Professional Documents
Culture Documents
A THERMADYNE® Company
Instruction Manual
A procedure which, if not properly followed, may • Do not use the plasma torch in an area where com-
cause injury to the operator or others in the oper- bustible or explosive gases or materials are located.
ating area. • Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
1.02 Important Safety Precautions
ELECTRIC SHOCK
WARNING
Electric Shock can injure or kill. The plasma arc process
OPERATION AND MAINTENANCE OF uses and produces high voltage electrical energy . This
PLASMA ARC EQUIPMENT CAN BE DAN- electric energy can cause severe or fatal shock to the op-
GEROUS AND HAZARDOUS TO YOUR erator or others in the workplace.
HEALTH. • Never touch any parts that are electrically “live” or
To prevent possible injury, read, understand and “hot.”
follow all warnings, safety precautions and in- • Wear dry gloves and clothing. Insulate yourself
structions before using the equipment. Call 1- from the work piece or other parts of the welding
603-298-5711 or your local distributor if you have circuit.
any questions.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
GASES AND FUMES • Install and maintain equipment according to NEC
code, refer to item 4 in Subsection 1.03, Publica-
Gases and fumes produced during the plasma cutting tions.
process can be dangerous and hazardous to your health. • Disconnect power source before performing any ser-
vice or repairs.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume. • Read and follow all the instructions in the Operat-
ing Manual.
1 GENERAL INFORMATION
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
FIRE AND EXPLOSION
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
Fire and explosion can be caused by hot slag, sparks, or
• Use the shade of lens as recommended in Subsec-
the plasma arc.
tion 1.03, item 4.
• Be sure there is no combustible or flammable mate-
rial in the workplace. Any material that cannot be 1.03 Publications
removed must be protected.
Refer to the following standards or their latest revisions
• Ventilate all flammable or explosive vapors from for more information:
the workplace.
1. OSHA, SAFETY AND HEALTH STANDARDS,
• Do not cut or weld on containers that may have
29CFR 1910, obtainable from the Superintendent of
held combustibles.
Documents, U.S. Government Printing Office, Wash-
• Provide a fire watch when working in an area where ington, D.C. 20402
fire hazards may exist. 2. ANSI Standard Z49.1, SAFETY IN WELDING AND
• Hydrogen gas may be formed and trapped under CUTTING, obtainable from the American Welding
aluminum workpieces when they are cut under- Society, 550 N.W. LeJeune Rd, Miami, FL 33126
water or while using a water table. DO NOT cut 3. NIOSH, SAFETY AND HEALTH IN ARC WELD-
aluminum alloys underwater or on a water table ING AND GAS WELDING AND CUTTING, obtain-
unless the hydrogen gas can be eliminated or dis- able from the Superintendent of Documents, U.S.
sipated. Trapped hydrogen gas that is ignited will Government Printing Office, Washington, D.C. 20402
cause an explosion. 4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-
CUPATION AND EDUCATIONAL EYE AND FACE
PROTECTION, obtainable from American National
NOISE
Standards Institute, 1430 Broadway, New York, NY
10018
Noise can cause permanent hearing loss. Plasma arc pro- 5. ANSI Standard Z41.1, STANDARD FOR MEN’S
cesses can cause noise levels to exceed safe limits. You SAFETY-TOE FOOTWEAR, obtainable from the
must protect your ears from loud noise to prevent per- American National Standards Institute, 1430 Broad-
manent loss of hearing. way, New York, NY 10018
• To protect your hearing from loud noise, wear pro- 6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
tective ear plugs and/or ear muffs. Protect others USE OF CUTTING AND WELDING PROCESSES,
in the workplace. obtainable from American National Standards Insti-
tute, 1430 Broadway, New York, NY 10018
• Noise levels should be measured to be sure the deci-
7. AWS Standard A6.0, WELDING AND CUTTING
bels (sound) do not exceed safe levels.
CONTAINERS WHICH HAVE HELD COMBUS-
• For information on how to test for noise, see item 1 TIBLES, obtainable from American Welding Society,
in Subsection 1.03, Publications, in this manual. 550 N.W. LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PRO-
PLASMAARC RAYS
CESSES, obtainable from the National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA
Plasma Arc Rays can injure your eyes and burn your 02269
skin. The plasma arc process produces very bright ultra 9. NFPA Standard 70, NATIONAL ELECTRICAL
violet and infra red light. These arc rays will damage CODE, obtainable from the National Fire Protection
your eyes and burn your skin if you are not properly Association, Batterymarch Park, Quincy, MA 02269
protected. 10. NFPA Standard 51B, CUTTING AND WELDING
• To protect your eyes, always wear a welding hel- PROCESSES, obtainable from the National Fire Pro-
met or shield. Also always wear safety glasses with tection Association, Batterymarch Park, Quincy, MA
02269
side shields, goggles or other protective eye wear .
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-
• Wear welding gloves and suitable clothing to pro-
PRESSED GASES IN CYLINDERS, obtainable from
tect your skin from the arc rays and sparks.
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 1.05 Precautions De Securite
WELDING AND CUTTING, obtainable from the Ca-
nadian Standards Association, Standards Sales, 178 Importantes
Rexdale Boulevard, Rexdale, Ontario, Canada M9W
1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRA- AVERTISSEMENT
PHY obtainable from the National Welding Supply
Association, 1900 Arch Street, Philadelphia, PA 19103
L’OPÉRATION ET LA MAINTENANCE DU
14. American Welding Society Standard AWSF4.1, REC- MATÉRIEL DE SOUDAGE À L’ARC AU JET
OMMENDED SAFE PRACTICES FOR THE PREPA- DE PLASMA PEUVENT PRÉSENTER DES
RATION FOR WELDING AND CUTTING OF CON- RISQUES ET DES DANGERS DE SANTÉ.
TAINERS AND PIPING THAT HAVE HELD
HAZARDOUS SUBSTANCES, obtainable from the Il faut communiquer aux opérateurs et au person-
American Welding Society, 550 N.W. LeJeune Rd, nel TOUS les dangers possibles. Afin d’éviter les
Miami, FL 33126 blessures possibles, lisez, comprenez et suivez tous
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA- les avertissements, toutes les précautions de
TORY PROTECTION, obtainable from American sécurité et toutes les consignes avant d’utiliser le
National Standards Institute, 1430 Broadway, New matériel. Composez le + 603-298-5711 ou votre
York, NY 10018 distributeur local si vous avez des questions.
3 GENERAL INFORMATION
• Utilisez un équipement spécial tel que des tables de • Prévoyez une veille d’incendie lors de tout travail
coupe à débit d’eau ou à courant descendant pour dans une zone présentant des dangers d’incendie.
capter la fumée et les gaz. • Le gas hydrogène peut se former ou s’accumuler
• N’utilisez pas le chalumeau au jet de plasma dans sous les pièces de travail en aluminium lorsqu’elles
une zone où se trouvent des matières ou des gaz sont coupées sous l’eau ou sur une table d’eau. NE
combustibles ou explosifs. PAS couper les alliages en aluminium sous l’eau
• Le phosgène, un gaz toxique, est généré par la fumée ou sur une table d’eau à moins que le gas hydrogène
provenant des solvants et des produits de nettoyage peut s’échapper ou se dissiper . Le gas hydrogène
chlorés. Eliminez toute source de telle fumée. accumulé explosera si enflammé.
Les chocs électriques peuvent blesser ou même tuer . Le Les rayons provenant de l’arc de plasma peuvent blesser
procédé au jet de plasma requiert et produit de l’énergie vos yeux et brûler votre peau. Le procédé à l’arc de plasma
électrique haute tension. Cette énergie électrique peut produit une lumière infra-rouge et des rayons ultra-vio-
produire des chocs graves, voire mortels, pour l’opérateur lets très forts. Ces rayons d’arc nuiront à vos yeux et
et les autres personnes sur le lieu de travail. brûleront votre peau si vous ne vous protégez pas
correctement.
• Ne touchez jamais une pièce “sous tension” ou
“vive”; portez des gants et des vêtements secs. • Pour protéger vos yeux, portez toujours un casque
Isolez-vous de la pièce de travail ou des autres par- ou un écran de soudeur. Portez toujours des lunettes
ties du circuit de soudage. de sécurité munies de parois latérales ou des lu-
• Réparez ou remplacez toute pièce usée ou nettes de protection ou une autre sorte de protec-
endommagée. tion oculaire.
• Prenez des soins particuliers lorsque la zone de tra- • Portez des gants de soudeur et un vêtement
vail est humide ou moite. protecteur approprié pour protéger votre peau
contre les étincelles et les rayons de l’arc.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la • Maintenez votre casque et vos lunettes de protec-
page 5, article 9.) tion en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Débranchez l’alimentation électrique avant tout tra-
vail d’entretien ou de réparation. • Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant
• Lisez et respectez toutes les consignes du Manuel des cabines ou des écrans de protection.
de consignes.
• Respectez le teint de lentille recommandé dans le
article 4, page 5.
INCENDIE ET EXPLOSION
BRUIT
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, Le bruit peut provoquer une perte permanente de l’ouïe.
des scories chaudes pouvant mettre le feu aux matières Les procédés de soudage à l’arc de plasma peuvent
combustibles ou provoquer l’explosion de fumées provoquer des niveaux sonores supérieurs aux limites
inflammables. normalement acceptables. V ous dú4ez vous protéger les
oreilles contre les bruits forts afin d’éviter une perte
• Soyez certain qu’aucune matière combustible ou in- permanente de l’ouïe.
flammable ne se trouve sur le lieu de travail.
Protégez toute telle matière qu’il est impossible de • Pour protéger votre ouïe contre les bruits forts, portez
retirer de la zone de travail. des tampons protecteurs et/ou des protections
• Procurez une bonne aération de toutes les fumées auriculaires. Protégez également les autres
inflammables ou explosives. personnes se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer
• Ne coupez pas et ne soudez pas les conteneurs ayant
que les décibels (le bruit) ne dépassent pas les
pu renfermer des matières combustibles.
niveaux sûrs.
GENERAL INFORMATION 4
• Pour des renseignements sur la manière de tester le 9. Norme 70 de la NFP A, CODE ELECTRIQUE NA-
bruit, consultez l’article 1, page 5. TIONAL, disponible auprès de la National Fire Pro-
tection Association, Batterymarch Park, Quincy, MA
1.06 Documents De Reference 02269
Consultez les normes suivantes ou les révisions les plus 10. Norme 51B de la NFP A, LES PROCÉDÉS DE
récentes ayant été faites à celles-ci pour de plus amples COUPE ET DE SOUDAGE, disponible auprès de
renseignements : la National Fire Protection Association,
Batterymarch Park, Quincy, MA02269
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAILET
11. Brochure GCA P-1, LA MANIPULA TION SANS
DE PROTECTION DE LA SANTÉ, 29CFR 1910,
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès du Superintendent of Docu-
disponible auprès de l’Association des Gaz
ments, U.S. Government Printing Office, Washing-
Comprimés (Compressed Gas Association), 1235
ton, D.C. 20402
Jef ferson Davis Highway, Suite 501, Arlington, VA
2. Norme ANSI Z49.1, LA SÉCURITÉ DES 22202
OPÉRATIONS DE COUPE ET DE SOUDAGE,
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR
disponible auprès de la Société Américaine de
LE SOUDAGE ET LA COUPE, disponible auprès
Soudage (American Welding Society), 550 N.W.
de l’Association des Normes Canadiennes, Stan-
LeJeune Rd., Miami, FL 33126
dards Sales, 178 Rexdale Boulevard, Rexdale,
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES Ontario, Canada, M9W 1R3
OPÉRATIONS DE COUPE ET DE SOUDAGE À
13. ivret NWSA, BIBLIOGRAPHIE SUR LASÉCURITÉ
L’ARC ET AU GAZ, disponible auprès du Super-
DU SOUDAGE, disponible auprès de l’Association
intendent of Documents, U.S. Government Print-
Nationale de Fournitures de Soudage (National
ing Office, Washington, D.C. 20402
Welding Supply Association), 1900 Arch Street,
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA Philadelphia, PA19103
PROTECTION DES YEUX ET DU VISAGE AU
14. Norme AWSF4.1 de l’Association Américaine de
TRAVAIL ET DANS LES ECOLES, disponible de
Soudage, RECOMMANDATIONS DE PRATIQUES
l’InstitutAméricain des Normes Nationales (Ameri-
SURES POUR LA PRÉP ARATION À LACOUPE
can National Standards Institute), 1430 Broadway,
ET AU SOUDAGE DE CONTENEURS ET
New York, NY 10018
TUYAUX AYANT RENFERMÉ DES PRODUITS
5. Norme ANSI Z41.1, NORMES POUR LES DANGEREUX , disponible auprès de la American
CHAUSSURES PROTECTRICES, disponible Welding Society, 550 N.W. LeJeune Rd., Miami, FL
auprès de l’American National Standards Institute, 33126
1430 Broadway, New York, NY10018
15. Norme ANSI Z88.2, PRATIQUES DE PROTEC-
6. Norme ANSI Z49.2, PRÉVENTION DES TION RESPIRATOIRE, disponible auprès de
INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS l’American National Standards Institute, 1430
DE COUPE ET DE SOUDAGE, disponible auprès Broadway, New York, NY 10018
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 LACOUPE DE
CONTENEURS AYANT RENFERMÉ DES
PRODUITS COMBUSTIBLES, disponible auprès de
la American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Pro-
tection contre les Incendies (NFP A), LES SYSTEMES
À GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la
National Fire ProtectionAssociation, Batterymarch
Park, Quincy, MA02269
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 manufac-
ture a unit and date of manufacture.
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.
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 WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such
as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter
“Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal
with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the
manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal whether arising out of contract,
negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the
goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR
THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Thermal products shall be as follows (with the exception of STAK PAK II): A maximum of three
(3) years from date of sale to an authorized distributor and a maximum of two (2) years from date of sale by such distributor to
the Purchaser, and with the following further limitations on such two (2) year period. The limited warranty period for STAK
PAK II shall be as follows: A maximum of four (4) years from date of sale to an authorized distributor and a maximum of three
(3) years from date of sale by such distributor to the Purchaser, and with the following further limitations on such three (3) year
period:
PARTS
PAK UNITS, POWER SUPPLIES STAK PAK II All OTHERS LABOR
MAIN POWER MAGNETICS ............................................................ 3 YEARS .............. 2 YEARS ................ 1 YEAR
ORIGINAL MAIN POWER RECTIFIER ........................................... 3 YEARS .............. 2 YEARS ................ 1 YEAR
CONTROL PC BOARD ....................................................................... 3 YEARS .............. 2 YEARS ................ 1 YEAR
ALL OTHER CIRCUITS AND COMPONENTS ............................... 1 YEAR ................ 1 YEAR ................. 1 YEAR
INCLUDING, BUT NOT LIMITED TO, STARTING
CIRCUIT, CONTACTORS, RELAYS, SOLENOIDS, PUMPS,
POWER SWITCHING SEMI-CONDUCTORS
CONSOLES, CONTROL EQUIPMENT, HEAT ................................... 1 YEAR ................ 1 YEAR ................ 1 YEAR
EXCHANGES, AND ACCESSORY EQUIPMENT
TORCH AND LEADS ............................................................................. 180 DAYS ............. 180 DAYS ............. 180 DAYS
REPAIR/REPLACEMENT PARTS ......................................................... 90 DAYS ............... 90 DAYS ................. NONE
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Arc® repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation
charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods
shall be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Thermal Arc® is a Registered Trademark of Thermal Dynamics.
Effective February 1, 1995
7 GENERAL INFORMATION
GENERAL INFORMATION 8
SECTION 2: GENERAL DESCRIPTION
2.01 SYSTEM DESCRIPTION
The Pak Master® 50 • Pak Master® 50 - The power supply provides 35 amp maximum
Air Plasma Cutting output and includes all control circuitry, electrical and gas
System Includes: 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.
Pak Master 50
Power Supply
CSD
RR
T CU
PILO
DC
S
GA
N PIP
RU
MP
ON TE
AC
T
SE
F
OF
RE
Torch
SU
ES
S PR
H GA
RC
TO
WOR
K
with Leads
Work Cable
with Clamp
A-00750
1.06 in 3.09 in
(27 mm) (78 mm)
8.95 in
(227 mm)
Pak Master 50 • Remote Control (RC) Wire Harness ...................... Cat. No. 9-6210
System Options and For converting a hand cutting system to mechanized use with a
Accessories 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 (N2) ............. Cat. No. 9-2722
• Running Gear ............................................................ Cat. No. 7-3201
For transporting the system with torch and leads storage.
• Air Line Filter - Single Stage ................................... Cat. No. 7-3265
Air Line Filter - Two Stage ...................................... Cat. No. 7-3340
Remove damaging moisture and contaminants from the air
stream when using compressed air.
• 575V Transformer Unit ............................................ Cat. No. 9-6211
For operating standard systems with 575V three-phase input.
Torch Options • Spare Parts Kit - MaximumLife™ .......................... Cat. No. 5-6001
and Accessories 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.
What's Included Torches are packaged separately. Included with each torch is:
with the Torch
(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
Choosing a Location Select a clean, dry location with good ventilation and adequate
working space around all components.
The power supply is cooled by air flow through the rear panel.
Air flow must not be obstructed. Provide at least 2 feet (0.61 m) of
clearance in the rear. Provide at least 6 inches (0.15 m) clearance
on each side. Provide sufficient clearance in front of the unit to
allow access to front panel controls (minimum 6 in or 0.15 m).
CAUTION Operation without proper air flow will inhibit proper cooling and
reduce duty cycle.
Hand Torch Set-Up The torch parts (shield cup, tip, electrode, and gas distributor)
must correspond with the type of operation (drag cutting, stand-
off cutting, or gouging). Refer to Torch Parts Selection (page 31).
The torch is factory assembled with the control switch in the top
front position (see Figure 3-A below). To position the control
switch on the bottom (underside) of the handle, pull the handle
back approximately 2 inches (51 mm) and rotate the handle
assembly 180° (do not rotate beyond 180°). To position the
control switch in the rear position:
1. Locate the tab on the back of the switch track closure. Gently
press in on the tab and carefully pry the closure upward.
2. Remove the switch track insert and the torch control switch.
3. Reinstall the switch track insert, then the switch, then the
switch track closure.
The optional switch lever kit provides a lever for activating the
torch control switch. Refer to Torch Options and Accessories
(page 80) for ordering information.
Switch Track
Switch Lever
with Mounting
Brackets
(Optional)
Bottom mounted
torch switch (shown
with optional switch lever)
Machine Torch Set-Up The torch parts (shield cup, tip, electrode, and gas distributor)
must correspond with the type of operation (drag cutting, stand-
off cutting, or gouging). Refer to Torch Parts Selection (page 23).
Metal mounting tubes with rack and pinion assemblies are
standard for machine torches. Phenolic (plastic) mounting tubes
with pinch blocks are optional (see Torch Options and Accesso-
ries, page 80).
1. Mount the torch assembly on the cutting table.
Refer to Figure 3-B and:
2. To obtain a clean vertical cut, use a square to align the torch
perpendicular to the surface of the workpiece.
A-00057
CAUTION This system is designed for use with the PCH/M-35 torch only.
Do not connect any other torch to this power supply.
Installing the Torch 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.
D
CS
U RR
OT C
PIL
DC
S
GA
N PIP
RU
MP
ON TE
AC
T
SE
OFF
E
UR
SS
RE
SP
H GA
Torch Leads
RC
TO
Connector
RK
WO
RC Wire Harness Installation of the remote control (RC) wire harness is required
for machine torch systems. Installation requires four #6-32 screws
with locknuts.
J6 Connector
Ground Wire
Hole Marked
“REMOTE
CONTROL”
Pak Master
Rear Panel
Ground Stud
(Inside Rear Panel) A-00752
Install the Wire Harness 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.
CAUTION 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 recep-
tacle in the hole from INSIDE the unit).
Reassemble the 7. Before reassembling the power supply enclosure, check that
Enclosure 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 compo-
nents 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.
Primary Input Voltages The unit can accept any input voltage from 200V to 460V (± 10%),
single or three phase, 50 or 60 Hz. 575V input requires an addi-
tional step-down transformer (Catalog No. 9-6211).
460V
HIGH LOW
TE
MO L
RE TRO
N
380/415V
CO
200/220V
380/415/460 200/220
VAC TE
VAC
MO L
RE TRO
N
CO
0-2
20 AC
V
40
Detail of Voltage Connection Panel
W
LO
H -
80
HIG 3
40
0-2
20 AC
0- V
20
60
0-4
38 AC
V
A-00753
CAUTION Both input voltage settings on the power supply must correspond
to the actual primary input voltage.
Input Power Cable Systems ordered for 230V operation come supplied with a 230V
Connections 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.
CAUTION 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).
Ground Wire
Input Power
Cable
A-00756
TE
MO L
RE TRO
N
CO
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.
E
UR
SS
RE
SP
H GA
RC
TO
WO
CAUTION Max input pressure must not exceed 125 psi (8.6 BAR/860kPa)
CAUTION 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.
Checking Air Quality 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!
Filtering 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.
Gas Connections 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 Refer to the manufacturer's specifications for installation and
Gas Cylinders 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 high-
pressure 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.
7. Set the high pressure regulator to 100 psi and adjust the unit
regulator for the desired 70 psi.
CAUTION Always open the high pressure cylinder valve slowly to prevent
damage to the unit gas regulator.
Using Shop Air 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)
Nylon Screw
Receptacles
Air Filter
Assembly
Female
JIC
Male
1/4 NPT
Rear Panel Fitting
A-00759
(1/4 NPT)
ON RUN
CSD
40 60
3 4
2 5
20
80
1 6
TORCH bar
psi
100
WORK
INDICATOR FUNCTION
1. ON/OFF Switch ON position supplies AC power to activate all system control circuits. OFF
position deactivates control circuits.
2. RUN/SET Switch RUN position is used for torch operation. SET position is used for setting gas
pressure and purging lines.
3. AC Indicator Green LED light indicates AC input power is present in the system when the
ON/OFF switch is in ON position.
4. TEMP Indicator Green LED light indicates proper operating temperature range. Red light
indicates overheating; unit must be allowed to cool.
5. PIP (Parts-In-Place) Yellow LED light indicates proper torch assembly. Light goes out if the shield
Indicator cup is not fully seated against the PIP pins in the torch body.
6. GAS Indicator 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.
7. DC Indicator Yellow LED light indicates adequate DC power output for main arc when the
torch is activated.
8. PILOT Indicator 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 Sets corner slowdown (CSD) output to a percentage of main output. Minimum
Adjustment output during CSD is 15 amps. Turn fully clockwise for maximum output (100%
of main current) during CSD. See Corner Slowdown Operation, page 29.
12. Pressure Control Adjusts pressure from the regulator. Pull knob out and turn clockwise to
increase pressure to desired level.
ACTION ACTION
Protect eyes and Torch moved away
activate torch. from work (while
still activated).
RESULT
RESULT
Gas flows.
GAS indicator on. Main arc stops.
Pilot arc auto-
After gas pre-flow: matically restarts.
DC indicator on. PILOT indicator on.
Power supply enabled.
HF relay closes.
Pilot arc established.
PILOT indicator on. ACTION
PILOT ARC Torch moved within
transfer distance of
workpiece.
RESULT
Main arc transfer.
ACTION Pilot arc off.
Torch deactivated (by torch switch PILOT indicator off.
release or by remote device). DC indicator still on.
RESULT
Main arc stops. Pilot stops.
(Power supply enable signal removed.)
DC indicator off.
PILOT indicator off.
ACTION
NOTE - If torch is activated during
ON/OFF switch
post-flow, pilot arc will immediately restart.
to OFF. ACTION
If torch is within transfer distance (3/8 in) of
workpiece, main arc will transfer. RESULT Open external
disconnect.
After post-flow: All indicators off.
Gas solenoid closes, gas flow stops. Power supply RESULT
GAS indicator off. fan off. No power to system.
Torch Parts Selection The torch parts (shield cup, tip, electrode, and gas distributor)
must correspond with the type of operation (drag cutting, stand-
off 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
MaximumLife™ Parts 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
CAUTION Do not use MaximimLife™ parts with standard parts.
MaximimLife™ shield cup attachment (No. 9-6503) must be
installed over the standard shield cup.
MaximumLife™ Parts
Standoff Drag
Heavy Duty Drag Tip Gouging Tip
Cutting Tip (.031 in) Cutting Tip (.031 in)
(.036 in) (.046)
Catalog No. 9-6500 Catalog No. 9-6501
Catalog No. 9-6120 Catalog No. 9-6002
Kerf Width
Cut Surface
Bevel Angle
Top
Spatter
Top Edge
Rounding
Dross
Build-Up
Cut Surface A-00007
Drag Lines
Description of Cut Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip orifice
Characteristics 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.
CAUTION Sparks from the cutting process can cause damage to coated,
painted, and other surfaces such as glass, plastic and metal.
NOTE Handle torch leads with care and protect them from damage.
Piloting 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.
Torch Standoff 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 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.
Direction of Cut 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.
Dross 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.
Dross High speed dross usually forms a narrow bead along the bottom
(continued) 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.
Cutting with a 1. The torch can be comfortably held in one hand or steadied
Hand Torch with two hands. Choose the technique that feels most com-
fortable 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 inter-
rupted, the pilot arc comes back on automatically.
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.
Piercing with a 1. When piercing with a hand torch, tip the torch slightly so that
Hand Torch blowback particles blow away from the torch tip (and opera-
tor) 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 anti-
spatter compound will minimize the amount of scale which
adheres to it.
Using Corner Slowdown The corner slowdown (CSD) function provides a reduction in
for Mechanized Cutting 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 slow-
down 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.
Tools Required Small Standard (Slotted Head) Screwdriver
Setting CSD Output 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.
Cutting with a The machine torch can be activated by remote control pendant or
Machine Torch 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 work-
piece 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
Dir
ect
ion
of T
orc
hT
rav Standoff Distance
el
Straight Arc
Trailing Arc
Piercing with a To pierce with a machine torch, the arc should be started with the
Machine Torch torch positioned as high as possible above the plate while allow-
ing 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 pen-
etrates 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.
CAUTION 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 Selec-
tion (page 31).
Standoff Distance 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 Build-up 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 build-
up 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.
CAUTION Do not blow air into the power supply during cleaning. Blowing
air into the unit can cause metal particles to interfere with sensi-
tive electrical components and cause damage to the unit.
NOTE 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.
Gas Standard
Distributor Shield Cup
Cleaning the Torch 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.
Checking the The center insulator separates the negative and positive charged
Center Insulator 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.
Pinion Assembly
Retaining Nut
PIP Connectors
Switch
Insert
Torch
Switch
Figure 5-C Removing the Torch Control Switch (PCH-35 Hand Torch)
Negative/Plasma
Lead Connection
A-00011
PIP Connectors
Handle
O-Rings
Torch Head Mounting Screws
CAUTION Do not lift the PIP pin receptacles out of the split holder to avoid
damage to holder and/or PIP pin receptacles may occur.
Replacing the 5. Position both PIP leads through the notch where the nega-
PIP Assembly tive/plasma lead exits the holder.
(continued)
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.
CAUTION Do not force the holder together. Damage to the insulation on the
leads will cause torch head failure. The PIP leads must be posi-
tioned correctly to allow reassembly of the torch head.
Bend wires to
fit grooves
Position PIP wires through
strain relief bosses as shown
A-00158
Split Holder
NOTE 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.
Reassembling the 1. Slide the inner retaining ring and outer retaining nut onto the
Quick Disconnect Fitting 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.
Signal Pin
Connector
Gently press tabs inward
and remove connector
Quick Disconnect
Body (Torch End)
(Reverse View)
Pilot Lead
Connection
Negative/Plasma
Lead Connection
A-00013
A B
10 11 12 13 14
6 7 8 9
1 2 3 4 5
A-00018
Pins Description
3, 4 Torch Switch
1, 6 Parts-In-Place (PIP)
13, 14 Shield (GND)
A Pilot Return - Positive
B Negative - Gas
Checking the 1. Remove the shield cup, tip, gas distributor, and electrode
Center Insulator 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 continu-
ity between the positive and negative torch quick disconnect
fittings. Infinite resistance (no continuity) should be found.
Checking the Torch 3. If there is continuity between the two torch quick disconnect
Head Connections 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.
Checking the 4. With the torch head disconnected from the leads, measure the
Torch Head 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 be-
tween 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 5. Slide the quick disconnect body, boot, and retaining ring back
Quick Disconnect (see Servicing Torch Leads Components, page 53). Visually
Assembly 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 prob-
lems 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 continu-
ity is found, replace the torch quick disconnect assembly.
Checking the 6. If the torch quick disconnect assembly is okay, check the
Torch Leads 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.
Reassembling the 7. Recheck the torch head, leads, and quick disconnect assembly
Torch and Leads to confirm proper measurements. If each component is found
to be okay, there is an assembly problem. Carefully reas-
semble the torch, leads, and quick disconnect and return to
step 2.
Basic and Advanced Two levels of troubleshooting are covered in the troubleshooting
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.
A. AC indicator not lit. 1. Input power not properly 1. Check that input power is
connected to input panel present and properly
connected (see Electrical
Connections, page 20)
2. Input power selection does 2. Check actual line voltage
not correspond to actual vs. voltage selection on
input voltage rear panel (see Electrical
Connections, page 20)
3. Input fuse blown 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. Faulty LDD PC board* 4. Check and replace if
necessary (see Service
Procedures, page 66)
B. AC indicator lit. TEMP 1. Unit is overheated 1. Make sure the unit has not
indicator red been operated beyond 70%
duty cycle limit
2. Fan not running (or 2. Check for obstructed air
airflow obstructed) flow (see Service Proce-
dures, page 67)
3. Faulty LDD board* 3. Check and replace if
necessary (see Service
Procedures, page 66)
C. AC indicator lit, TEMP 1. Torch not properly con- 1. Check that quick discon-
indicator green, PIP nected to power supply nect is properly attached
indicator not lit
2. Shield cup not properly 2. Check that shield cup is
installed on torch fully seated against torch
head (do not overtighten)
3. Faulty PIP assembly in 3. Check PIP assembly (see
torch holder Servicing Torch Head
Components, page 44)
4. Faulty pins inside torch 4. Check for continuity
quick disconnect between pins 1 and 6.
Check that pins in either
half of quick disconnect
are not pushed back. See
Figure 5-H (page 55)
D. AC indicator lit, TEMP 1. Gas not connected or 1. Check source for at least
indicator green, PIP pressure too low 70 psi (4.8 BAR). In SET
indicator lit, GAS indicator position, adjust gas pres-
not lit sure to 70 psi
2. Faulty pressure switch* 2. Check and replace if
necessary. See Service
Procedures (page 65)
3. Faulty regulator* 3. Check and replace if
necessary. See Service
Procedures (page 65)
4. Faulty LDD board* 4. Check and replace if
necessary. See Service
Procedures (page 65)
E. When power is applied to 1. RUN/SET switch in SET 1. Set switch to RUN position
unit, GAS indicator position
remains lit for more than
2. Faulty LDD board* 2. Check and replace if
20 seconds
necessary. See Service
Procedures (page 65)
3. Faulty solenoid*
3. Check and replace if
necessary. See Service
Procedures (page 65)
F. Torch will not pilot when 1. Switch activated during 20 1. Release switch and wait at
torch switch is activated second pre-flow least 20 seconds before
activating switch again
2. Faulty torch parts 2. Inspect torch parts and
replace if necessary (see
Replacing Consumable
Torch Parts, page 44)
3. Gas pressure too high 3. Set pressure to 70 psi (4.8
BAR)
4. Faulty high frequency 4. Check spark gap assembly
trigger circuit* (see Service Procedures,
page 65)
G. DC indicator not lit when 1. Switch activated during 20 1. Release switch and wait at
torch switch is activated second pre-flow least 20 seconds before
activating switch again
2. DC output not present* 2. Check DC output (see
Section 5.08, page 68)
H. Torch pilots but does not 1. Torch too far from 1. Hold torch 1/8 inch (3
cut workpiece mm) from workpiece
2. Work lead not connected 2. Make sure work lead is
connected securely (check
continuity if necessary)
3. Power supply not sensing 3. Check D23 indicator on
transfer current* LDD board. If not lit, send
unit to an authorized
service center
I. Torch cuts but not ad- 1. Current set too low 1. Increase current setting
equately
2. Torch is being moved too 2. Reduce cutting speed (see
fast across workpiece Cutting Speeds, page 40)
3. Excessive oil or moisture 3. Hold torch 1/8 inch (3
in torch mm) from clean surface
while purging and observe
oil or moisture buildup
(do not activate torch)
Opening the Enclosure 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 care-
fully lift the upper enclosure half from the chassis.
Main Transformer (T3) 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.
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
Fuse 1FU
Main Transformer (T3)
Regulator/Solenoid/
High Frequency Transformer (T2)
Gauge Assembly
Work Lead Inductor (L7) 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.
Main Output Inductor The only reason the main output choke should be replaced is if
(L6) 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.
Solenoid/Regulator/ To check the solenoid, measure for 115 VAC between wires 18
Switch/Gauge Assembly 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.
Replacing the Since the LDD board contains no high power circuitry, but does
LDD Board 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.
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.
DC Output Check 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.
Reassembling the Before reassembling the power supply enclosure, check that all
Enclosure 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.
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
8 2
11
2
7
10
12
A-00763
13
1
8
4
7
3 2
A-00764
5
8
7
6
2
3 1
12
10 11
4
16
15
9
14
13
5
A-00774
16
15
13
14
3
5
9
7
12
11
10
A-00775
16
5
13 6
(5)
10
14 3
2 11
15 1
12 A-00776
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)
4 5
8
1 2
8
8
3
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
CAUTION
Standoff Drag
Heavy Duty Drag Tip Gouging Tip
(.046)
Cutting Tip (.031 in) Cutting Tip (.031 in)
(.036 in)
Catalog No. 9-6002 Catalog No. 9-6500 Catalog No. 9-6501
Catalog No. 9-6120
7
2
10
1
12
11
13
A-00804