PakMaster 100XL Plus Operating Manual (0-2811) - Jun2003

Automated Plasma
Cutting Power Supply

PAK Master 100XL Plus
A-02751
Operating Manual
June 26, 2003
Manual No. 0-2811
WARNINGS
Read and understand this entire Manual and your employers safety practices before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the
Manufacturer's best judgement, the Manufacturer assumes no liability for
its use.
Automated Plasma Cutting Power Supply

Pak Master 100XL Plus
Operating Manual Number 0-2811
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 2000 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 this Manual,
whether such error results from negligence, accident, or any other cause.
Printed in the United States of America
Publication Date: June 26, 2003
Record the following information for Warranty purposes:
Where Purchased:____________________________________
Purchase Date:_______________________________________
Power Supply Serial #:________________________________
Torch Serial #:________________________________________
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ............................................................................................... 1-1
1.01
1.02
1.03
1.04
1.05
1.06
1.07
1.08
Notes, Cautions and Warnings ..................................................................... 1-1

Important Safety Precautions ....................................................................... 1-1
Publications .................................................................................................. 1-2
Note, Attention et Avertissement .................................................................. 1-3
Precautions De Securite Importantes ........................................................... 1-3
Documents De Reference ............................................................................ 1-5
Declaration of Conformity ............................................................................. 1-7
Statement of Warranty .................................................................................. 1-8
SECTION 2:
INTRODUCTION .............................................................................................................. 2-1
2.01
2.02
2.03
2.04
Scope of Manual .......................................................................................... 2-1

General Description of System ..................................................................... 2-1
Specifications/Design Features .................................................................... 2-1
Power Supply Options and Accessories ....................................................... 2-3
SECTION 3:
INSTALLATION ................................................................................................................. 3-1
3.01
3.02
3.03
3.04
3.05
3.06
3.07
3.08
3.09
3.10
3.11
3.12
Introduction .................................................................................................. 3-1

Site Selection ............................................................................................... 3-1
Unpacking .................................................................................................... 3-1
Lifting Options .............................................................................................. 3-1
Input Power Connections ............................................................................. 3-2
Input Voltage Selection ................................................................................. 3-2
Primary Input Power Cable Connections ...................................................... 3-3
Gas Connections ......................................................................................... 3-4
Connecting Torch Leads ............................................................................... 3-6
Ground Connections For Mechanized Applications ...................................... 3-8
Tip Saver/Drag Cut Sensing Circuit ............................................................ 3-10
External Control Connections ..................................................................... 3-10
SECTION 4:
OPERATION ..................................................................................................................... 4-1
4.01
4.02
4.03
4.04
4.05
Introduction ................................................................................................. 4-1

Operating Controls ...................................................................................... 4-1
Sequence of Operation ................................................................................ 4-3
Preparations for Operating .......................................................................... 4-4
Cut Quality .................................................................................................. 4-5
TABLE OF CONTENTS (continued)

SECTION 5:
SERVICE .......................................................................................................................... 5-1
5.01
5.02
5.03
5.04
5.05
Introduction .................................................................................................. 5-1

General Maintenance ................................................................................... 5-1
Common Operating Problems ...................................................................... 5-2
Troubleshooting Guide ................................................................................. 5-4
Power Supply Parts Replacement ................................................................ 5-6
SECTION 6:
PARTS LISTS .................................................................................................................... 6-1
6.01
6.02
6.03
6.04
6.05
Introduction ................................................................................................. 6-1

Ordering Information ................................................................................... 6-1
Complete Power Supply Replacement ........................................................ 6-2
Replacement Parts ...................................................................................... 6-2
Options and Accessories ............................................................................. 6-2
APPENDIX I: INPUT WIRING REQUIREMENTS ..................................................................... A-1

APPENDIX II: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ......................................... A-2
APPENDIX III: POWER SUPPLY CNC INTERFACE DIAGRAM ............................................... A-3
APPENDIX IV: DATA TAG INFORMATION ................................................................................ A-4
APPENDIX V: SYSTEM SCHEMATIC ...................................................................................... A-6
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
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.
Throughout this manual, notes, cautions, and warnings

are used to highlight important information. These highlights are categorized as follows:
Use an air-supplied respirator if ventilation is not

adequate to remove all fumes and gases.
NOTE
The kinds of fumes and gases from the plasma arc

depend on the kind of metal being used, coatings
on the metal, and the different processes. You must
be very careful when cutting or welding any metals which may contain one or more of the following:
An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
Antimony
Arsenic
Barium
Beryllium
Cadmium
A procedure which, if not properly followed, may

cause damage to the equipment.
Chromium
Cobalt
Copper
Lead
Manganese
Mercury
Nickel
Selenium
Silver
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.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
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.
1.02 Important Safety Precautions
Use special equipment, such as water or down draft

cutting tables, to capture fumes and gases.
WARNINGS
Do not use the plasma torch in an area where 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.
OPERATION AND MAINTENANCE OF

PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEALTH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health
equipment to determine whether a hazard exists.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any
questions.
Date: November 15, 2001
This product, when used for welding or cutting,

produces fumes or gases which contain chemicals
known to the State of California to cause birth defects and, in some cases, cancer. (California Health
& Safety Code Sec. 25249.5 et seq.)
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.
1-1
GENERAL INFORMATION
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 9 in Subsection 1.03, Publications.
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.
Disconnect power source before performing any

service or repairs.
Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
Read and follow all the instructions in the Operating Manual.
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

the plasma arc.
Use the shade of lens as suggested in the following

per ANSI/ASC Z49.1:
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.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You
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.
GENERAL INFORMATION
Minimum Protective
Shade No.
Suggested
Shade No.
Less Than 300*
300 - 400*
12
400 - 800*
10
14
* These values apply where the actual arc is clearly

seen. Experience has shown that lighter filters
may be used when the arc is hidden by the workpiece.
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.
Arc Current
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, Washington,
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, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MENS
SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New
York, NY 10018
1-2
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE

OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430
Broadway, New York, NY 10018
ATTENTION
Toute procdure pouvant rsulter
lendommagement du matriel en cas de nonrespect de la procdure en question.
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
AVERTISSEMENT
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
Toute procdure pouvant provoquer des blessures

de loprateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procdure en question.
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
1.05 Precautions De Securite

Importantes
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
AVERTISSEMENTS
LOPRATION ET LA MAINTENANCE DU
MATRIEL DE SOUDAGE LARC AU JET
DE PLASMA PEUVENT PRSENTER DES
RISQUES ET DES DANGERS DE SANT.
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
Coupant larc au jet de plasma produit de lnergie

lectrique haute tension et des missions
magntique qui peuvent interfrer la fonction
propre dun pacemaker cardiaque, les appareils
auditif, ou autre matriel de sant electronique.
Ceux qui travail prs dune application larc au
jet de plasma devrait consulter leur membre
professionel de mdication et le manufacturier de
matriel de sant pour dterminer sil existe des
risques de sant.
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY

obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION 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
Il faut communiquer aux oprateurs et au personnel TOUS les dangers possibles. Afin dviter les
blessures possibles, lisez, comprenez et suivez tous
les avertissements, toutes les prcautions de scurit
et toutes les consignes avant dutiliser le matriel.
Composez le + 603-298-5711 ou votre distributeur
local si vous avez des questions.
1.04 Note, Attention et

Avertissement
Dans ce manuel, les mots note, attention, et
avertissement sont utiliss pour mettre en relief des
informations caractre important. Ces mises en relief
sont classifies comme suit :
NOTE
Toute opration, procdure ou renseignement
gnral sur lequel il importe dinsister davantage
ou qui contribue lefficacit de fonctionnement
du systme.
FUME et GAZ
La fume et les gaz produits par le procd de jet de
plasma peuvent prsenter des risques et des dangers de
sant.
1-3
GENERAL INFORMATION
Eloignez toute fume et gaz de votre zone de respiration. Gardez votre tte hors de la plume de fume
provenant du chalumeau.
Utilisez un appareil respiratoire alimentation en air
si laration fournie ne permet pas dliminer la fume
et les gaz.
Les sortes de gaz et de fume provenant de larc de
plasma dpendent du genre de mtal utilis, des
revtements se trouvant sur le mtal et des diffrents
procds. Vous devez prendre soin lorsque vous
coupez ou soudez tout mtal pouvant contenir un ou
plusieurs des lments suivants:
antimoine
argent
arsenic
baryum
bryllium
cadmium
chrome
cobalt
cuivre
manganse
mercure
nickel
plomb
slnium
vanadium
Lisez toujours les fiches de donnes sur la scurit

des matires (sigle amricain MSDS); celles-ci
devraient tre fournies avec le matriel que vous
utilisez. Les MSDS contiennent des renseignements
quant la quantit et la nature de la fume et des gaz
pouvant poser des dangers de sant.
Pour des informations sur la manire de tester la
fume et les gaz de votre lieu de travail, consultez
larticle 1 et les documents cits la page 5.
Ne touchez jamais une pice sous tension ou vive;

portez des gants et des vtements secs. Isolez-vous
de la pice de travail ou des autres parties du circuit
de soudage.
Rparez ou remplacez toute pice use ou
endommage.
Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
Montez et maintenez le matriel conformment au
Code lectrique national des Etats-Unis. (Voir la page
5, article 9.)
Dbranchez lalimentation lectrique avant tout travail dentretien ou de rparation.
Lisez et respectez toutes les consignes du Manuel de
consignes.
INCENDIE ET EXPLOSION
Les incendies et les explosions peuvent rsulter des scories
chaudes, des tincelles ou de larc de plasma. Le procd
larc de plasma produit du mtal, des tincelles, des
scories chaudes pouvant mettre le feu aux matires combustibles ou provoquer lexplosion de fumes
inflammables.
Utilisez un quipement spcial tel que des tables de

coupe dbit deau ou courant descendant pour
capter la fume et les gaz.
Soyez certain quaucune matire combustible ou inflammable ne se trouve sur le lieu de travail. Protgez
toute telle matire quil est impossible de retirer de la
zone de travail.
Nutilisez pas le chalumeau au jet de plasma dans une

zone o se trouvent des matires ou des gaz combustibles ou explosifs.
Procurez une bonne aration de toutes les fumes

inflammables ou explosives.
Le phosgne, un gaz toxique, est gnr par la fume

provenant des solvants et des produits de nettoyage
chlors. Eliminez toute source de telle fume.
Ce produit, dans le procder de soudage et de coupe,
produit de la fume ou des gaz pouvant contenir des
lments reconnu dans Ltat de la Californie, qui
peuvent causer des dfauts de naissance et le cancer.
(La scurit de sant en Californie et la code scurit
Sec. 25249.5 et seq.)
Ne coupez pas et ne soudez pas les conteneurs ayant

pu renfermer des matires combustibles.
Prvoyez une veille dincendie lors de tout travail dans
une zone prsentant des dangers dincendie.
Le gas hydrogne peut se former ou saccumuler sous
les pices de travail en aluminium lorsquelles sont
coupes sous leau ou sur une table deau. NE PAS
couper les alliages en aluminium sous leau ou sur
une table deau moins que le gas hydrogne peut
schapper ou se dissiper. Le gas hydrogne accumul
explosera si enflamm.
CHOC ELECTRIQUE
Les chocs lectriques peuvent blesser ou mme tuer. Le
procd au jet de plasma requiert et produit de lnergie
lectrique haute tension. Cette nergie lectrique peut
produire des chocs graves, voire mortels, pour loprateur
et les autres personnes sur le lieu de travail.
GENERAL INFORMATION
RAYONS DARC DE PLASMA

Les rayons provenant de larc de plasma peuvent blesser
vos yeux et brler votre peau. Le procd larc de
plasma produit une lumire infra-rouge et des rayons
1-4
ultra-violets trs forts. Ces rayons darc nuiront vos

yeux et brleront votre peau si vous ne vous protgez
pas correctement.
Pour protger vos yeux, portez toujours un casque ou
un cran de soudeur. Portez toujours des lunettes de
scurit munies de parois latrales ou des lunettes de
protection ou une autre sorte de protection oculaire.
Portez des gants de soudeur et un vtement protecteur
appropri pour protger votre peau contre les
tincelles et les rayons de larc.
Maintenez votre casque et vos lunettes de protection
en bon tat. Remplacez toute lentille sale ou
comportant fissure ou rognure.
Protgez les autres personnes se trouvant sur la zone
de travail contre les rayons de larc en fournissant des
cabines ou des crans de protection.
Utilisez la nuance de lentille qui est suggre dans le
recommendation qui suivent ANSI/ASC Z49.1:
Courant Arc
Nuance Minimum
Protective Numro
Nuance Suggere
Numro
Moins de 300*
300 - 400*
12
400 - 800*
10
14
* Ces valeurs sappliquent ou larc actuel est observ

clairement. Lexperience a dmontrer que les filtres
moins foncs peuvent tre utiliss quand larc est
cach par moiceau de travail.
BRUIT
Le bruit peut provoquer une perte permanente de loue.
Les procds de soudage larc de plasma peuvent
provoquer des niveaux sonores suprieurs aux limites
normalement acceptables. Vous d4ez vous protger les
oreilles contre les bruits forts afin dviter une perte
permanente de loue.
Pour protger votre oue contre les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protgez galement les autres personnes
se trouvant sur le lieu de travail.
Il faut mesurer les niveaux sonores afin dassurer que
les dcibels (le bruit) ne dpassent pas les niveaux
srs.
Pour des renseignements sur la manire de tester le
bruit, consultez larticle 1, page 5.
1.06 Documents De Reference

Consultez les normes suivantes ou les rvisions les plus
rcentes ayant t faites celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SCURIT DU TRAVAIL ET DE
PROTECTION DE LA SANT, 29CFR 1910,
disponible auprs du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. Norme ANSI Z49.1, LA SCURIT DES
OPRATIONS DE COUPE ET DE SOUDAGE,
disponible auprs de la Socit Amricaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SCURIT ET LA SANT LORS DES
OPRATIONS DE COUPE ET DE SOUDAGE
LARC ET AU GAZ, disponible auprs 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 lInstitut
Amricain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York,
NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible auprs
de lAmerican National Standards Institute, 1430
Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRVENTION DES INCENDIES
LORS DE LEMPLOI DE PROCDS DE COUPE ET
DE SOUDAGE, disponible auprs de lAmerican National Standards Institute, 1430 Broadway, New York,
NY 10018
7. Norme A6.0 de lAssociation Amricaine du Soudage
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS AYANT RENFERM DES PRODUITS
COMBUSTIBLES, disponible auprs de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
8. Norme 51 de lAssociation Amricaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES
GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCDS ASSOCIS, disponible auprs de la National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269
1-5
GENERAL INFORMATION
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprs de la National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
10. Norme 51B de la NFPA, LES PROCDS DE
COUPE ET DE SOUDAGE, disponible auprs de la
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMS EN CYLINDRES,
disponible auprs de lAssociation des Gaz
Comprims (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202
12. Norme CSA W117.2, CODE DE SCURIT POUR
LE SOUDAGE ET LA COUPE, disponible auprs
de lAssociation des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA
SCURIT DU SOUDAGE, disponible auprs de
lAssociation Nationale de Fournitures de Soudage
(National Welding Supply Association), 1900 Arch
Street, Philadelphia, PA 19103
14. Norme AWSF4.1 de lAssociation Amricaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRPARATION LA COUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX
AYANT
RENFERM
DES
PRODUITS
DANGEREUX , disponible auprs de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRATOIRE, disponible auprs de lAmerican
National Standards Institute, 1430 Broadway, New
York, NY 10018
GENERAL INFORMATION
1-6
1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation
Address:
82 Benning Street
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/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for
the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit
and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related
industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure
the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.
Manufacturers responsible representative:
Giorgio Bassi
Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy
1-7
GENERAL INFORMATION
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 Thermals 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 Thermals sole
option, of any components or parts of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but
not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter Purchaser) for
service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any
contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,
resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any
warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar
and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from
date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).
The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).
Parts
PAK Units, Power Supplies
XL Plus &
CutMaster Series
Parts
Cougar/Drag-Gun
Parts
All Others
Labor
Main Power Magnetics
3 Years
1 Year
2 Years
1 Year
Original Main Power Rectifier
3 Years
1 Year
2 Years
1 Year
Control PC Board
3 Years
1 Year
2 Years
1 Year
All Other Circuits And Components Including,

But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
Consoles, Control Equipment, Heat

Exchanges, And Accessory Equipment
1 Year
Torch And Leads

Maximizer 300 Torch
SureLok Torches
1 Year
All Other Torches
180 Days
180 Days
180 Days
180 Days
90 Days
90 Days
90 Days
None
Repair/Replacement Parts
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges
to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the
customers risk and expense. This warranty supersedes all previous Thermal warranties.
Effective: November 15, 2001
GENERAL INFORMATION
1-8
SECTION 2:
INTRODUCTION
2.01 Scope of Manual
This manual contains descriptions, operating instructions,
and basic maintenance procedures for the PAK Master
100XL Plus Automated Plasma Cutting Power Supply
only. Service of this equipment is restricted to properly
trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty.
Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it
was designed.
Various torches are available with the Power Supply. The

Machine Torch is available in a 180 configuration. Torch
leads are available in 25 ft (7.6 m), or 50 ft (15.2 m) lengths
with fittings for simple installation. Spare Parts Kits are
available for the torches which provide an assortment of
replacement torch parts.
NOTES
Refer to Section 2.04 for a list of power supply options and accessories.
2.03 Specifications/Design Features

A. Power Supply Technical Specifications
The following specifications apply to the Power Supply
only:
1. Front Panel Controls
ON/OFF Switch, RUN/SET/LATCH Switch and
Output Current Control
2.02 General Description of System

The Automated System includes a Power Supply, Torch
& Leads and Work Cable & Ring Terminal.
The Power Supply provides 80 amp maximum output
and includes all control circuitry, electrical and gas inputs and outputs, pilot circuitry, torch leads receptacle
and a work cable with ring terminal.
2. Front Panel Indicators

AC
, GAS
, DC
3. Rear Panel
Input Power Cable Strain Relief, Gas Connection, Gas
Regulator/Filter Assembly, Two Stage Air Filter, CNC
Connector
NOTE
The power supply can be ordered in various configurations with various options factory installed.
, TEMP
4. Input Power
Can be configured for the following input power:
208/230/240 VAC (10%), 50/60 Hz, Single or ThreePhase
Power Supply
380/415 VAC (10%), 50/60 Hz, Three-Phase
Torch and
Leads
460 VAC (10%), 50/60 Hz, Single or Three-Phase
A-02750
Work Cable and

Ring Terminal
Figure 2-1 Pak Master 100XL Plus Automated

System
Manual 0-2811
2-1
INTRODUCTION
5. Output Power
C. Two Stage Air Line Filter Specifications
Continuously variable from 15 to 80 Amps maximum

6. Duty Cycle (Refer to NOTE)
The following specifications apply to the Two Stage Air

Line Filter Assembly only:
NOTE
PakMaster 100XLP (Automated)

Duty Cycle
The two stage air line filter is for use on systems

using compressed air.
104 F
(40 C)
Ambient
Temperature
1. Air Flow
15 scfm (425 lpm)
Duty Cycle
40%
60%
100%
Current
80 Amps
n/a
60 Amps
NOTE
DC Voltage
112 vdc
n/a
112 vdc
Depending on the moisture in the air source the

weep drain on the bottom of the Filter should be
left open 1/4 turn at all times. The weep drain will
allow 10 scfh (10.7 lpm) of air to escape using 100
psi line pressure in the closed position. This will
allow water, oil and contamination to escape from
the filter.
NOTE
The duty cycle will be reduced if the primary input voltage (AC) is low or the DC voltage is higher
than shown in the chart.
2. Maximum input pressure
7. Cut Capacity (Mild Steel)
250 psi (17.2 bar)
Production: 3/8 inch (9.5 mm)
3. Dew Point
Genuine: 1 inch (25.4 mm)
10 to 35 F (-12 to 1.7 C) @ Atmospheric Pressure
Severance: 1-1/4 inch (31.8 mm)
4. Filtration
8. Pilot Circuitry
5 micron
Capacitive Discharge (CD), Pulsed DC

9. Weight
68 lbs ( 31 kg) w/work lead
75 lbs ( 34 kg) w/work lead, torch & lead
10. Overall Dimensions
19" (482 mm) High x 10.5" (267 mm) Wide x 24.8"
(630 mm) Long
Overall dimensions are with Handle, Gas Regulator/
Filter Assembly and Two Stage Air Filter installed.
B. Gas Regulator/Filter Assembly

Specifications
The following specifications apply to the Gas Regulator/
Filter Assembly only:
1. Gas regulator maximum gauge pressure
160 psi (11 bar)
2. Maximum input gas pressure
125 psi (8.6 bar)
3. Filter
Coalescent type filter
INTRODUCTION
2-2
Manual 0-2811
2.04 Power Supply Options and

Accessories
NOTE
Refer to Section 6, Parts Lists, for part numbers
and ordering information.
The following are accessories that are available for this
power supply:
A. Single Stage Air Line Filter Kit

A Single Stage In-Line Air Filter which is a pneumatic
dryer/evaporator that installs in the plasma or secondary compressed air line. Filters moisture, oil, dirt,
chips, rust particles, and other contaminants.
B. High Pressure Regulators

High pressure regulators are available for air and nitrogen. The regulators are used to set the proper pressure for the type gas being used.
C. 575V Transformer
This step-down transformer allows the power supply to operate with 575 VAC three-phase input power.
D. Computer Control Cable (CNC)

The interface cable is available in two lengths, 25 ft
(7.6 m) and 50 ft (15.2 m). The cable is used to interface the power supply with an auxiliary control device to provide OK-To-Move, ON/OFF signals and
standoff control signals.
E. Single-Phase Input Power Cable (220 VAC)

Input power cable with molded plug for applications
using single-phase 220 VAC input power.
F. Multi-Purpose Cart
Rugged steel cart on easy-rolling rear wheels and
front-mounted swivel casters. Provides maximum
mobility for the power supply and can also serve as
a display cart. Top shelf is 12 " (305 mm) x 20 (508
mm). Steel handle is 30" (762 mm) high.
Manual 0-2811
2-3
INTRODUCTION
INTRODUCTION
2-4
Manual 0-2811
SECTION 3:
INSTALLATION
3.01 Introduction
NOTE
Depending on how the system was ordered, some
Power Supply options may already be installed.
If option(s) have been factory installed some of the
instructions may not apply. It is recommended
that all subsections be read for general information.
This section describes installation of the Power Supply
and connecting the Torch.
These instructions apply to the Power Supply only; installation procedures for the Torch, Options, and Accessories are given in Manuals specifically provided for those
units.
The complete installation consists of:
1. Site selection
CAUTION
Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.
3.03 Unpacking
Each component of the system is packaged and protected
with a carton and packing material to prevent damage
during shipping.
1. Unpack each item and remove all packing material.
NOTE
The Cutting Spare Parts Kit is shipped in the Torch
Leads Storage Area on the side of the Power Supply.
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.
3.04 Lifting Options
2. Unpacking
3. Connections to Power Supply
WARNINGS
a. Input Power
b. Gas
Do not touch live electrical parts.
c. Work Cable
Disconnect input power conductors from de-energized supply line before moving unit.
d. Torch Leads
4. Grounding
This unit is equipped with one handle mounted onto the

top of the enclosure for hand carrying purposes.
5. Operator training
3.02 Site Selection
WARNING
Select a clean, dry location with good ventilation and adequate working space around all components.
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
NOTE
Review Important Safety Precautions (Section 1)
to be sure that the selected location meets all safety
requirements.
Lift unit with the handle on top of the enclosure.

Only persons of adequate physical strength should
lift the unit.
The power supply is fan cooled by air flow through the

front panel to the rear panel. Air flow must not be obstructed. Provide at least 2 feet (0.6 m) in the rear and at
least 6 inches (0.15 m) on each side for clearance. Provide
sufficient clearance in front of the unit to allow access to
the front panel controls (minimum 6 inches or 0.15 m).
Manual 0-2811
Use hand cart or similar device of adequate capacity.

If using a fork lift vehicle, place and secure unit on
a proper skid before transporting.
3-1
INSTALLATION
This unit has a handle mounted on top of the enclosure for hand lifting only. Be sure unit is lifted and
transported safely and securely.
Left Side
Panel
WARNING
HANDLE is not for mechanical lifting.
3.05 Input Power Connections

A-02761
The Power Supply accepts input voltages from 208V to

460V. Input can be 50 or 60 Hz, single-phase or threephase. Depending on how the Power Supply was ordered
the Power Supply is factory wired for 230V single-phase
or 460V three-phase input. For any other input voltage,
the Power Supply must be internally reset.
Screws
(5 places)
NOTE
Figure 3-1 Removing Left Side Panel
Refer to Section 3.06, Input Voltage Selection for

procedure.
NOTE
A. Input Voltage Selection

The Power Supply is factory-wired for 230V single-phase
or 460V three-phase input depending on the order. For
any other input voltage, the Power Supply must be
changed using the procedure in Section 3.06.
B. Electrical Connections
There is a ground wire connection to the Left Side

Panel on the inside of the unit.
2. Carefully pull the Left Side Panel up and away from
the unit to gain access to the inside of the unit.
3.06 Input Voltage Selection

NOTE
The power source must conform to local and national electric codes. Recommended circuit protection and wiring
requirements are shown in Appendix I.
For power supplies to use 575 VAC input power,

the unit must be setup for 460V three-phase operation and the 575V Transformer Accessory must
be installed.
C. Opening Power Supply Enclosure

The left side panel of the Power Supply must be removed
to gain access to the input power connections and the
input voltage selection.
WARNING
The Power Supply has three voltage settings; 208/230/

240VAC, 380/415VAC, or 460VAC. Power Supplies are
factory-wired for 230V single-phase or 460VAC threephase input depending on the order. Input voltage selection is accomplished by switching an internal buss bar
and connector inside the Power Supply. Also, for singlephase operation a jumper wire must be properly installed.
Disconnect primary power at the source before assembling or disassembling the Power Supply, torch
parts, or torch and leads assemblies.
WARNING
1. Remove the five screws which secure the left side

panel (viewed from front of unit) to the frame assembly.
Disconnect primary power at the source before assembling or disassembling the power supply, torch
To change the voltage selection use the following procedure as required:
INSTALLATION
3-2
Manual 0-2811
1. Pull the single wire voltage selection plug from the

connector mounted on the internal center chassis.
Voltage Selection
Plug (460V)
Voltage Selection
Plug (220V)
3.07 Primary Input Power Cable

Connections
Units ordered as 230V, single-phase, will have a six foot
power input cable and plug factory installed. For all other
units, a cable must be provided by the end user. Recommended cable sizes are specified in Appendix I.
460V
380415V
380-415V/460V
220V
220V
220V
220V
380-415V/460V
380415V
460V
Voltage Selection
Plug (380-415V)
A-01361
A. Primary Power Cable Connection

Procedure
1. Route the primary power cable through the strain relief fitting in the rear panel of the Power Supply and
tighten strain relief screws.
AC Input Power
Cable Strain Relief
Figure 3-2 Voltage Selection Plug

2. Loosen the screws securing the voltage selection block
to the terminal block.
3. Pull the voltage selection block up and out from the
terminal block.
4. Turn the voltage selection block to the desired voltage to be used. Use 220V for units using 208/230/
240V input and 380-415V/460V for 380/415V or 460V
input power.
5. Slide the voltage selection block onto the terminal
block and tighten all the screws.
NOTE
A-00912
Figure 3-4 AC Input Power Cable Strain Relief

2. Connect the input cable inside the Power Supply for
the type of operation as follows:
Three-Phase Operation
All screws must be tightened even if not used on

the terminal block.
Voltage Selection
Block
AC Input
Power Cable
Three-phase operation requires a 3-conductor cable

with ground.
a. Locate the ground stud and remove the top
nut and washer.
A-01347
b. Install a lug terminal on the ground wire.

460V
380415V
380-415V/460V
220V
220V
220V
c. Place the ground wire onto the ground stud

and secure with the nut and washer.
220V
380-415V/460V
380415V
460V
d. Insert the other three wires into the L1, L2, and
L3 terminals on the contactor.
208/230/240VAC
e. Tighten all set screws.
380-415V/460VAC
f. Verify unused jumper wire is connected only

to the L3 terminals.
Figure 3-3 Voltage Selection Block Installation
NOTE
6. Move the voltage selection plug to the desired input

connector for 220V (208/230/240V), 380/415V, or
460V input power operation.
Manual 0-2811
The jumper wire from L1 to L4 must not be removed.
3-3
INSTALLATION
Input
Contactor
c. Locate the ground stud and remove the top

nut and washer.
L3
d. Install a lug terminal on the ground wire.
L2
e. Place the ground wire onto the ground stud

and secure with the nut and washer.
L1
f. Insert the other two wires into the L1 and L2

terminals on the contactor.
g. Tighten all set screws even the ones not used.
A-02670
Input Contactor
L2
L1
Unused Jumper
L3 to L3 (storage)
AC Input
Power Cable
GND
Figure 3-5 Primary Power Cable Connections Three-Phase Operation

A-00915
Single-Phase Operation
Single-phase operation requires a 2-conductor cable
with ground.
GND
AC Input
Power Cable
a. Locate the single-phase jumper wire connected

between the two L3 terminal lugs on the input contactor.
Figure 3-7 Primary Power Cable Connections Single-Phase Operation
b. Move one end of the jumper wire from terminal lug L3 to L2 at the contactor.
3.08 Gas Connections
NOTE
The jumper wire from L1 to L4 must not be removed.
Input Contactor
A. Gas Requirements
WARNING
L3
L2
This unit not to be used with oxygen (O2).

Gases: Compressed Air or Nitrogen (N2) Only
Pressure:
70 psi (4.8 bar)

CAUTION
Maximum input gas pressure must not exceed 125

psi (8.6 bar)
A-00914
Single Phase
Jumper Wire
(L2 to L3)
Flow:
Cutting - 400 scfh (188.7 lpm)
Gouging - 400 scfh (188.7 lpm)
Figure 3-6 Single Phase Jumper Wire Installation
INSTALLATION
3-4
Manual 0-2811
B. Checking Air Quality
D. Optional Air Line Filter Installation
To test the quality of air, place the RUN/SET/LATCH

switch to SET position, place a welding filter lens in front
of the torch and turn on the gas. Any oil or moisture in
the air will be visible on the lens. Do not initiate an arc!
Filtering is required when using air from a compressor to

ensure that moisture and debris from the supply hose do
not enter the torch. Although the unit is standard with
the Two Stage Air Filter there is an Optional Single-Stage
Filter Assembly that may be used. Install the Optional
Single-Stage Filter as follows:
CAUTION
1. Remove the air hose connected between the Two

Stage Air Filter OUT port and the Regulator/Filter Assembly.
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.
2. Connect the gas line to the Regulator / Filter Assembly inlet port as shown. The illustration shows
typical fittings as an example. Other fittings may
be used. Install the fittings and tighten.
C. Gas Connections
The gas supply is connected to the Two Stage Air Line
Filter Assembly installed on the rear of the unit. The connection is the same for compressed air or high pressure
gas cylinders.
NOTE
Supply hose must be at least #4 hose (1/4 in or 6
mm I.D.).
Connect the gas supply as follows:

NOTE
mm I.D.).
Dry Air Filter
Assembly
A-02744
1/4 NPT to
#4 (6mm)
Hose Fitting
1/4 NPT to
#4 (6mm) Hose
Fitting
Hose Clamp
#4 (6mm)
Gas Supply
Hose
Hose Clamp
#4 (6mm) Gas Two Stage Filter

Supply Hose
Assembly
A-02753
Figure 3-9 Gas Connection to Optional Single-Stage

Filter Assembly
Figure 3-8 Gas Connection To Two Stage Filter

Assembly
Manual 0-2811
3-5
INSTALLATION
E. Using High Pressure Gas Cylinders
3.09 Connecting Torch Leads
Refer to the following when using high pressure gas cylinders as the gas supply:
WARNING
CAUTION
Disconnect primary power at the source before assembling or disassembling the power supply, torch
Pressure should be set at 100 psi (6.9 bar) at the

high pressure gas cylinder regulator.
Refer to the manufacturers specifications for
installation and maintenance procedures for
high pressure gas regulators.
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.
The cylinder must be equipped with an adjustable high-pressure regulator capable of
outlet pressures up to 100 psi (6.9 bar) maximum and flows of up to 300 scfh (141.5 lpm).
The Torch Leads must be properly installed to the Power

Supply for proper operation. Make all torch connections
to the Torch Bulkhead Panel as follows:
NOTE
Equipment ordered as a system will have the Torch
factory connected to the Power Supply.
1. Turn the screw latch securing the front access panel
to the power supply front panel.
1. Remove the air hose connected between the Two

Stage Air Filter OUT port and the Regulator/Filter Assembly.
Access
Panel
Screw
Latch
NOTE
mm I.D.).
A-02467
Figure 3-10 Front Access Panel

2. Lift up the access panel for access to the torch bulkhead panel.
CAUTION
This system is designed for use with the PCM-102
Automated Torch or the SL100 Machine Torch
only. Do not connect any other torch to this power
supply.
INSTALLATION
3-6
Manual 0-2811
7. Place the lug on the Pilot Control Wire onto the

stud and secure with the nut and washer removed
in the above Step.
A. PCM-102 Torch Installation

1. Remove the retaining nut from the Strain Relief.
Strain Relief
8. Tighten the Strain Relief onto the Torch Leads.
Torch Leads
Assembly
9. Check the torch for proper parts assembly.

10. Close the access panel and turn the latching screw.
B. SL100 Torch Installation

A-02760
Torches with shielded leads and ATC connectors connect

to a shielded ATC Adapter which connects to the power
supply bulkhead. Torches with shielded leads and O2B
fittings connect directly to the power supply bulkhead.
Bulkhead connections are the same in both applications.
Strain Relief
Nut
WARNING
Figure 3-10 Torch Strain Relief Nut

Disconnect primary power at the source before disassembling the torch or torch leads.
2. Feed the end of the torch lead and the Strain Relief into the hole in the unit.
3. Tighten the Strain Relief Nut to secure the Strain
Relief to the Power Supply.
Shielded ATC Adapter

A-03677
Adapter
Connector
Adapter
(Supplied With
Power Supply)
Pilot Lead Stud

Pilot Lead
PIP Circuit &

Shield Connectors
Strain Relief
Negative/Plasma
Lead
Shield
Connector
Gas/Power Lead
Connection
Torch Control
Connectors
Pilot Lead
Gas/Power
Lead
Torch Lead
Assembly
Strain Relief
Nut
Shield
Connector
Strain Relief Nut Removal

A-02747
1. Remove the Strain Relief Nut from the Strain Relief. Inside the Power Supply Bulkhead area, route
the connectors on the free end of the Adapter or
Torch Leads through the Strain Relief Nut.
Figure 3-11 Torch Leads Connections

4. Connect the torch Negative/Plasma Lead to the
bulkhead connection inside the Power Supply.
2. Fit the ATC Adapter or Torch Leads end and the

Strain Relief into the hole in the unit.
5. Connect the PIP and Shield Cables to the mating

connectors on the Adapter supplied on the Power
Supply.
3. Secure the Strain Relief with the retaining nut removed earlier.
6. Remove the top nut and washer from the Pilot

Stud.
Manual 0-2811
3-7
INSTALLATION
4. Connect the ATC Adapter or Torch Leads Negative / Plasma Lead to the bulkhead connection
inside the Power Supply.
10. Check the torch for proper consumable parts.

CAUTION
5. Remove the top nut and washer from the Pilot

Stud.
The torch parts must correspond with the type of

operation. Refer to the torch manual for details.
6. Connect the pilot lead terminal to the stud and

secure with the nut and washer removed previously.
7. Connect the ATC Adapter or Torch Leads connectors to the power supply adapter.
3.10 Ground Connections For

Mechanized Applications
A. Electromagnetic Interference (EMI)
Pilot arc initiation generates a certain amount of electromagnetic interference (EMI), commonly called RF noise.
This RF noise may interfere with other electronic equipment such as CNC controllers, remote controls, height
controllers, etc. To minimize RF interference, follow these
grounding procedures when installing mechanized systems:
WARNING
The Shielded ATC Adapter includes two connectors that are not used and must be taped out of the
way to prevent contacting the Negative / Plasma
or Pilot Leads.
B. Grounding
8. Tighten the Strain Relief onto the or Torch Leads

ATC Adapter leads.
9. In applications using the torches with ATC Connectors, connect the torch leads male connector
to the ATC female receptacle. The connectors
should push together with a very small amount
of pressure. Secure the connection by turning the
locking nut clockwise until it stops. DO NOT use
the locking nut to pull the connection together.
Do not use tools to secure the connections.
1. The preferred grounding arrangement is a single point

or Star ground. The single point, usually on the
cutting table, is connected with 1/0 AWG (European
50 mm2) or larger wire to a good earth ground (refer
to paragraph C, Creating An Earth Ground). The
ground rod must be placed as close as possible to the
cutting table, ideally less than 10 ft (3.0 m), but no
more than 20 ft (6.1 m).
NOTE
All ground wires should be as short as possible.
Long wires will have increased resistance to RF
frequencies. Smaller diameter wire has increased
resistance to RF frequencies, so using a larger diameter wire is better.
Torch Leads
ATC Male
Connector
To
Power Supply
ATC Adapter
Female Receptacle
2. Grounding for components mounted on the cutting

table (CNC controllers, height controllers, plasma remote controls, etc.) should follow the manufacturers
recommendations for wire size, type, and connection
point locations.
For Thermal Dynamics components it is recommended to use a minimum of 10 AWG (European 6

mm2) wire or flat copper braid with cross section equal
to or greater than 10 AWG connected to the cutting
table frame. The connection point must be clean bare
metal; rust and paint make poor connections. For all
components, wires larger than the recommended
minimum can be used and may improve noise protection.
A-03627
Torch Connection - Torch Leads with ATC Male

Connector, Power Supply with ATC Adapter
3. The cutting machine frame is then connected to the

Star point using 1/0 AWG (European 50 mm2) or
larger wire.
INSTALLATION
3-8
Manual 0-2811
4. The plasma power supply work cable (see NOTE) is

connected to the cutting table at the single point Star
ground.
NOTE
Ideally, a properly installed ground rod will have a
resistance of three ohms or less.
NOTE
To test for a proper earth ground, refer to the following diagram. Ideally, the reading on the multimeter
should be as follows:
Do Not connect the work cable directly to the

ground rod.
5. Make sure work cable and ground cables are properly connected. The work cable must have a solid
connection to the cutting table. The work and ground
connections must be free from rust, dirt, grease, oil
and paint. If necessary grind or sand down to bare
metal. Use lock washers to keep the connections tight.
Using electrical joint compound to prevent corrosion
is also recommended.
For 115VAC: 3.0 VAC

For 230VAC: 1.5 VAC
115VAC: 3.0 VAC

230VAC: 1.5 VAC
V~
6. The plasma power supply chassis is connected to the

power distribution system ground as required by electrical codes. If the plasma supply is close to the cutting table (see NOTE) a second ground rod is not usually needed, in fact it could be detrimental as it can
set up ground loop currents that cause interference.
Meter set to
VAC setting
WARNING
Use extreme caution. This
test uses live voltage.
When the plasma power supply is far away from the

ground rod and interference is experienced, it may
help to install a second earth ground rod next to the
plasma power supply. The plasma power supply
chassis would then be connected to this ground rod.
115 or 230VAC
It is recommended that the Plasma Power Supply

be within 20 - 30 ft (6.1 9.1 m) of the cutting
table, if possible.
Manual 0-2811
100W
Light Bulb
Line (Hot)
Machine
Earth Ground
A-02971
7. The plasma control cable should be shielded with the

shield connected only at the cutting machine end.
Connecting the shield at both ends will allow ground
loop currents which may cause more interference than
with no shield at all.
1. To create a solid, low resistance, earth ground, drive a

1/2 in (12 mm) or greater diameter copper clad ground
rod at least 6 - 8 ft (1.8 - 2.4 m) into the earth so that
the rod contacts moist soil over most of its length.
Depending on location, a greater depth may be required to obtain a low resistance ground (see NOTE).
Ground rods, typically 10 ft (3.0 m) long, may be
welded end to end for greater lengths. Locate the rod
as close as possible to the work table. Install a ground
wire, 1/0 AWG (European 50 mm2) or greater, between
the ground rod and the star ground point on the cutting table.
VR COM
_
+
Neutral
NOTE
C. Creating An Earth Ground
V~
Ground Testing
2. Increasing the ground rod length beyond 20 - 30 ft
(6.1 9.1 m) does not generally increase the effectiveness of the ground rod. A larger diameter rod which
has more surface area may help. Sometimes keeping
the soil around the ground rod moist by continuously
running a small amount of water into it will work.
Adding salt to the soil by soaking it in salt water may
also reduce its resistance. When these methods are
used, periodic checking of the ground resistance is required to make sure the ground is still good.
3-9
INSTALLATION
D. Routing Of Torch Leads
3.12 External Control Connections
1. To minimize RF interference, position torch leads as

far as possible from any CNC components, drive motors, control cables, or primary power lines. If cables
have to pass over torch leads, do so at an angle. Do
not run the plasma control or other control cables in
parallel with the torch leads in power tracts.
2. Keep torch leads clean. Dirt and metal particles bleed
off energy, which causes difficult starting and increased chance of RF interference.
3.11 Tip Saver/Drag Cut Sensing

Circuit
External control signal connections can be made to the

Rear Panel of the power supply. Connections can be made
to interface with CNC Controls, Standoff Control SC11
or Remote Hand Pendant.
Depending on the option installed determines how the
option is connected to the Power Supply.
A. Computer Control Interface (CNC)

NOTE
Used when Standoff Control SC11 are not used.
This power supply is equipped with a Tip Saver/Drag

Cut Sensing Circuit which cuts current back to 35 amps if
the tip touches the workpiece. The purpose of this is to
prolong the life of the tip.
The computer control interface (CNC) allows an automated system to interface with a computer or other control device.
CNC cables can be interfaced to the Power Supply using
one of the following methods:
If the user does not want the current to be decreased when

the tip touches the workpiece, the sensing circuit can be
defeated by closing switch SW1-1 on the Gate/Logic PC
Board. Slide top white toggle on SW1-1 to the right to
close circuit.
NOTE
Refer to Appendix III for CNC Interface Schematic.
Connector (J22) at the rear of the Power Supply
Internal terminal block in the Power Supply
Depending on the equipment ordered and the cables supplied connect the CNC cable per one of the following:
SW1
ON
1
2
1. Using supplied CNC cable

Connect the supplied Power Supply/CNC Cable
to the Power Supply rear panel connector J22
(CNC Control).
Gate/Logic PC Board
A-02569
Figure 3-14 SW1 Switch Location
WARNING
Tip life will be considerably shortened if tip is repeatedly touched to the workpiece without the Tip
Saver/Drag Sensing Circuit feature active.
INSTALLATION
3-10
Manual 0-2811
2. Using customer supplied CNC Cable

a. Remove the Left Side Panel from the Power
Supply as viewed from the front of the unit.
b. Remove the 7/8" knockout from the Rear
Panel and install a 1/2" NPT strain relief (not
supplied) into the hole.
d. Feed the CNC cable through the strain relief

at the rear of the Power Supply, routing the
cable above the Logic PC Board to the Terminal Block (TB).
CNC Cable Routing
Internal Terminal
Block (TB)
Rear Panel
CNC Knockout
1/2" (12.7 mm)

Strain Relief
(Customer Supplied)
A-02763
A-02756
Figure 3-15 Routing CNC Cable
Figure 3-13 Rear Panel Knockout Location

c. Locate the internal terminal block (TB) on the
Filter/Voltage Divider PC Board, located behind the Logic PC Board. The terminal block
(TB) is plugged into a socket on the Filter/Voltage Divider PC Board.
Filter/Voltage Divider
PC Board
Internal Terminal
Block (TB)
Logic PC Board
A-02762
Figure 3-14 Internal Terminal Block Location
Manual 0-2811
3-11
INSTALLATION
e. Remove the terminal block from the socket and

connect the CNC cable to the terminal block
(TB) per the following chart (see NOTES after
chart):
f. Reinstall the terminal block into the socket on

the Filter/Voltage Divider PC Board.
g. Secure the CNC cable by tightening the strain
relief.
h. Reinstall the Left Side Panel.
TB
Connection
B. Optional Standoff Control SC11 Cable
Description
Power Supply Output Voltage (ARC V +)
Power Supply Output Voltage (ARC V -)
High Side of START Signal (+15 vdc)
Low Side of START Signal (Common)
One Side of OK-To-Move Signal
The Standoff Control SC11 automatically finds height and

maintains torch standoff with a high speed torch lifter
motor. The unit consists of a remote operator's control,
torch lifter motor, and all cables required for installation.
It is ordered and shipped separately. Refer to the Standoff Control SC11 Instruction Manual for more information.
The standoff control remote cable connects to the receptacle J22 (CNC Control) on the rear panel of the Power
Supply.
A-02759
Other Side of OK-To-Move Signal
J22
CNC Connector
A-02754
ARC V.
START
OK TO
MOVE
6
CNC or Remote Hand
Pendant Control Cable
Figure 3-16 Terminal Block Positions

NOTES
Figure 3-17 Standoff Or Hand Pendant Control

Interface Connection
ARC V+ Power supply positive output voltage

(work lead) connection to TB position 1 through a
100k resistor.
ARC V- Power supply negative output voltage
(torch electrode) connection to TB position 2
through a 100k resistor.
START + signal at TB position 3, 15 vdc at 10 ma,
must be brought low by connecting it to START at TB position 4, using a switch or relay contact,
to start the plasma torch.
C. Optional Remote Hand Pendant Control

For automated systems, the optional Remote Hand Pendant Control allows the operator to control system start
and stop functions from a remote location.
Connect the Remote Hand Pendant cable connector to
the receptacle J22 (CNC Control) on the rear panel of the
Power Supply.
OK-To-Move is a relay, rated at 115 VAC/28 vdc

at 2A, connected to TB positions 5 and 6 which
closes for the OK-To-Move signal when the cutting arc is on.
Make sure all connections to the Terminal Block
(TB) are secure.
INSTALLATION
3-12
Manual 0-2811
4. Work Cable and Clamp
SECTION 4:
OPERATION
Work cable with ring terminal (factory installed) for

connecting to work table.
B. Control Panel
4.01 Introduction
This section provides a description of the Power Supply
operating controls and procedures. Identification of the
Front and Rear Panel components is followed by operating procedures.
4 5
40
6 7
60
4.02 Operating Controls
15
This subsection provides specific functional descriptions

of the Power Supply operating controls and indicators.
A. Front and Side Panel
80
1. Control Panel
All operator controls, except gas pressure adjustment,
are located on this panel. Power ON/OFF and RUN/
SET/LATCH switches; CURRENT control; indicators
for AC Power, TEMP, GAS, and DC.
A-03454
Figure 4-2 Operating Controls

1. Current Control (A)
Adjustment to set the desired output current between

15 to 80 amps. The unit has an automatic fold-back
circuit that limits current to 35 amps if torch tip contacts the workpiece.
2. ON
Power Switch
ON position supplies AC power to activate all system control circuits. OFF position deactivates control circuits.
A-02748
Figure 4-1 Front and Side Panel Connections
3. RUN
/LATCH
RUN position is used for torch operation. SET position used for setting gas pressure and purging lines.
NOTE
A panel for access to the bulkhead area containing

the torch connections.
The LATCH position is not used for automatated

system applications.
3. Torch Leads Input

Hole in the front panel to feed the torch leads through
to the internal bulkhead connections.
/SET
Switch
2. Access Panel
Manual 0-2811
/ OFF
4. AC Power
Indicator
Green indicator will blink ON then OFF for approximately eight seconds and then stay ON after the ON/
OFF power switch is set to ON. Indicates operating
power is present in the unit.
4-1
OPERATION
D. Rear Panel
5. TEMP
Indicator
1. Gas Input
Normally OFF. Yellow indicator turns ON when the

internal temperature senors detect temperatures
above normal limits. The unit should be allowed to
cool before continuing operation.
6. GAS
Input connection for air or nitrogen (N2) input.
WARNING
Indicator
This unit not to be used with oxygen (O2).
Green indicator turns ON when the input gas pressure is set to 45 psi (3.1 bar) or higher. Indicator will
be OFF when the pressure falls below 45 psi (3.1 bar).
7. DC
Indicator
Green indicator turns ON while the torch switch is

pressed.
5
C. Torch Bulkhead Panel
The torch bulkhead panel is under the access panel.

1. Pilot Lead Stud
Connects the pilot control wire on the torch to the
unit.
3
1
4
2
A-02746
Figure 4-4 Rear Panel

3
2. Primary Input Power Cable Strain Relief

A-00923
NOTE
Figure 4-3 Torch Panel Connections
Input power cable is supplied on units when ordered for 230V single-phase operation.
2. PIP/Shield Connector
Connects the torch PIP circuit and shield wires to the
unit with an adapter supplied with the Power Supply.
Primary input power cable strain relief for the primary power cable (see Note above) capable of handling the input voltage designed for this unit.
3. Gas Pressure Regulator/Filter Assembly
3. Gas/Power Lead Connection
Pressure regulator to adjust the input gas pressure to

the Power Supply. An air line filter is supplied as
part of the pressure regulator.
Connects the torch gas/negative lead to the unit.
OPERATION
4-2
Manual 0-2811
4. Two Stage Air Line Filter
4.03 Sequence of Operation
The Two Stage Air Filter will remove moisture and

contaminants from the air stream when using compressed air. The filter is capable of filtering to at least
5 microns.
The following is a typical sequence of operation for this

cutting system. Refer to Appendix II for a block diagram.
1. Close main power source disconnect.
5. CNC Connector (J22)
a. AC power is available at the Power Supply.

2. Place RUN/SET/LATCH switch to RUN mode.
External connector provided for connection of CNC

Control, Standoff Control SC11 or Remote Hand Pendant Control.
3. Place the ON/OFF power switch on the front panel

of the Power Supply to ON.
6. Knockout
indicator blinks ON and OFF

a. AC Power
for eight seconds then stays ON.
Knockout provided that allows internal connection

of CNC Control to a Terminal Block.
b. Fans turn on.
7. Optional Single-Stage Filter Assembly
4. Place RUN/SET/LATCH switch to SET mode.
This optional in-line filter removes moisture and contaminants from the air stream when using compressed air. The filter is capable of filtering to at least
0.85 microns.
a. Gas solenoid opens and gas flows to set pressure.

b. GAS
indicator turns ON.

NOTE
GAS indicator will not come ON if the gas pressure is set below 35 psi (2.4 bar) at the Regulator/
Filter Assembly.
5. Place RUN/SET/LATCH switch to RUN mode.
a. Gas flow stops.

b. GAS indicator turns OFF.
NOTE
Do Not use the LATCH position for automated

3
7
6. Protect eyes and activate system (CNC start signal or press Remote Pendant switch)
a. Gas pre-flows starts.
2
b. GAS indicator turns ON.
A-02749
7. After gas pre-flow (approximately 2 seconds)
a. Power supply enabled.

b. DC
indicator turns ON.
c. Pilot relay closes.
Figure 4-5 Rear Panel Showing Optional SingleStage Filter
8. Pilot arc is established

9. Torch moves to within transfer distance of workpiece.
a. Main arc transfers to workpiece..
b. Pilot arc OFF.
Manual 0-2811
4-3
OPERATION
10. Complete cutting operation.
4.04 Preparations for Operating
NOTE
Follow this set-up procedure each time the system is operated:
If the torch is lifted from the workpiece, while still

having torch is activated, the main arc will stop
and the pilot arc will automatically restart.
WARNING
11. Stop system (CNC stop signal or release Remote

Hand Pendant switch)
Disconnect primary power at the source before disassembling the power supply, torch, or torch leads.
a. Main arc stops.

b. Pilot arc stops (power supply enable signal removed).
NOTE
A. Torch Parts Selection
If torch is activated during post-flow, pilot arc will

immediately restart.
Check the torch for proper assembly and appropriate front

end torch parts. The torch parts (shield cup, tip and electrode) must correspond with the type of operation (cutting or gouging).
If torch is within 3/8 in (9.5mm) transfer distance

of workpiece, main arc will transfer.
B. Check Primary Power Source
12. Gas will flow for 15 seconds (post-flow).

a. Gas solenoid closes
b. Gas flow stops.
c. GAS indicator turns OFF.
13. Place the ON/OFF power switch on the front
panel of the unit to OFF
a. AC Power indicator turns OFF.
b. Fans turn OFF.
14. Place the main power disconnect to open.
a. Main AC power is removed from the system.
1. Check the power source for proper input voltage. Make

sure the input power source meets the power requirements for the unit per Section 2.03-A-4, Specifications/
Design Features.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
C. Gas Selection
Select desired gas (air or nitrogen). Make sure gas source
meets pressure and flow requirements (refer to Section
3.08, Gas Connections). Check connection and turn gas
supply on.
D. Work Cable Connection

Check for a solid and clean work cable connection to the
workpiece or cutting table. The area must be free from
paint and rust.
E. Torch Connection
Check that the torch is properly connected.
F. Power Supply On
Move the ON/OFF switch to ON position.
G. Select Output Current

Select the desired current output level for the operation:
15 to 80 amps for standoff cutting and gouging
15 to 35 amps for drag cutting
NOTE
At output settings over 35 amps, the power supply automatically reduces output current to 35
amps if the torch tip touches the workpiece.
OPERATION
4-4
Manual 0-2811
H. Set Operating Pressure
Nitride Build-up
Move the RUN/SET/LATCH switch to SET position. Adjust the gas pressure to 60 - 70 psi / 4.1 - 4.8 bar. Refer to
torch manual for pressure setting details.
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.
I. RUN/SET Switch
Set the RUN/SET/LATCH switch to RUN position.
Kerf Width
Cut Surface
Bevel Angle
NOTE
Do Not use the LATCH position for automated
Top
Spatter
The system is now ready for operation.

Top Edge
Rounding
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 4-6:
Cut Surface
The condition (smooth or rough) of the face of the cut.
Bevel Angle
Dross
Build-Up
Figure 4-9 Cut Quality Characteristics

Cut quality will vary on different types of and material
thicknesses.
The following table shows the cut quality that can be expected from this equipment for materials with a thickness from gage to 1 inch (25.4mm):
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.
G as
A ir
Top-Edge Rounding
Rounding on the top edge of a cut due to wearing from
the initial contact of the plasma arc on the workpiece.
Dross Build-up and Top Spatter
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.
Kerf Width
The width of material removed during the cut.
A-00007
Cut Surface
Drag Lines
N i trogen
C ar b o n
S t eel
G ood E x c ellent
G ood
T yp e o f M ater ial
S t ain less
A lu m in u m
S t eel
G ood G ood E x c ellent
E x c ellent
G ood
G ood
Description of Cut Characteristics

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.
NOTES
Cut quality depends heavily on set-up and parameters such as torch standoff, alignment with the
workpiece, cutting speed, gas pressures, and operator ability.
Manual 0-2811
4-5
OPERATION
OPERATION
4-6
Manual 0-2811
SECTION 5:
SERVICE
Weekly or Every 30 Cutting Hours:

1. Check fan for proper operation and adequate air
flow.
2. Vacuum dust and dirt out of the entire machine.
5.01 Introduction
CAUTION
This section describes basic maintenance procedures performable by operating personnel. No other adjustments
or repairs are to be attempted by other than properly personnel.
For major troubleshooting and parts replacement procedures refer to PAK Master 100XL Plus Automated
Power Supply Service Manual 0-2812.
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.
Six Months or Every 720 Cutting Hours:
1. Check the in-line air filter(s), clean or replace as
required
5.02 General Maintenance
2. Check cables and hoses for leaks or cracks, replace

if necessary.
WARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
3. Check all contactor points for severe arcing or pits,

replace if necessary.
B. Two Stage Air Filter Element Replacement

NOTE
To clean the unit, open the enclosure (refer to Section 5.05A, Opening Enclosure) 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.
The Two Stage Air Filter has two Filter Elements.

When the Filter Elements become dirty the Power
Supply will continue to operate but cut quality may
become unacceptable.
1. Remove power from power supply.
This schedule applies to all types of non-liquid cooled

plasma cutting systems. Some systems will not have all
the parts listed and those checks need not be performed.
2. Shut off air supply and bleed down system before disassembly before changing Filter Elements.
NOTE
The actual frequency of maintenance may need to
be adjusted according to the operating environment.
WARNING
Always turn off the air supply and bleed the system before disassembling the Filter Assembly as
injury could result.
A. Maintenance Schedule
Daily Operational Checks or Every Six Cutting Hours:
1. Check torch consumable parts, replace if damaged
or worn.
3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to
move freely.
2. Inspect torch for any cracks or exposed wires, replace if necessary.
4. Note the location and orientation of the old Filter

Elements.
3. Check plasma and secondary supply and pressure/flow.
5. Slide out the old Filter Elements.
4. Purge plasma gas line to remove any moisture

build-up.
6. Slide the replacement Filter Elements into the Filter Assembly the same as noted in Step 4 above.
5. Inspect input power cable for damage or exposed

wires, replace if necessary.
7. Hand tighten the two bolts evenly, then torque

each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm).
8. Slowly apply air pressure to the assembly checking for leaks.
Manual 0-2811
5-1
SERVICE
C. Optional Single-Stage Filter Element

Replacement
5.03 Common Operating Problems
NOTE
WARNINGS
The Power Supply shuts down automatically when

the Filter Element becomes completely saturated.
The Filter Element can be removed from its housing, dried out, and reused. Allow 24 hours for Element to dry.
Disconnect primary power at the source before disassembling the power supply, torch, or torch leads.
Frequently review the Important Safety Precautions (page 1). Be sure the operator is equipped with
proper gloves, clothing, eye and ear protection.
Make sure no part of the operators body comes into
contact with the workpiece while the torch is activated.
1. Remove power from power supply.

2. Shut off air supply and bleed down system before disassembly to change Filter Element.
CAUTION
Housing
Sparks from the cutting process can cause damage

to coated, painted, and other surfaces such as glass,
plastic and metal.
Filter
Element
(Cat. No. 9-7741)
NOTE
Handle torch leads with care and protect them from
damage.
Spring
A. Piloting
O-ring
Assembled Filter
Cover
Barbed
Fitting
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.
A-02476
B. Torch Standoff
Figure 5-1 Optional Single-Stage Filter Replacement
3. Disconnect gas supply hose.
4. Turn the Cover counterclockwise and remove it
from the Filter Housing. The Filter Element is located inside the Housing.
5. Remove the Filter Element from the Housing and
set Element aside to dry.
6. Wipe inside of housing clean, then insert the replacement Filter Element cup side first, as shown
below.
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 will generally result in a more
square cut.
C. Edge Starting
For edge starts, hold the torch perpendicular to the workpiece with the front of the tip at 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.
7. Replace Housing on Cover.

8. Reattach gas supply hose.
NOTE
If unit leaks between housing and cover, inspect
the "O" Ring for cuts or other damage.
SERVICE
5-2
Manual 0-2811
D. Direction of Cut
F. Common Cutting Faults
In the torch, the plasma gas stream swirls as it leaves the

torch to maintain a smooth column of gas. This 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 (Refer to Figure 5-2). To make a square-edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an
outside diameter cut, the torch should travel in a clockwise direction.
1. Insufficient Penetration
Left Side
Cut Angle
a. Cutting speed too fast

b. Torch tilted too much
c. Metal too thick
d. Worn torch parts
e. Cutting current too low
f. Non-Genuuite Thermal Dynamics parts
2. Main Arc Extinguishes
a. Cutting speed too slow
Right Side
Cut Angle
b. Torch standoff too high from workpiece

c. Cutting current too high
d. Work cable disconnected
e. Worn torch parts
A-00512
Figure 5-2 Side Characteristics Of Cut
3. Excessive Dross Formation

a. Cutting speed too slow
E. Dross
b. Torch standoff too high from workpiece
Generally when dross is present on carbon steel, it is referred to as either "high speed or slow speed dross".
"High speed dross" usually forms a narrow bead along
the bottom of the cut edge and is very difficult to remove.
"Slow speed dross" will be in larger quantities but does
not adhere tightly to the cut edge and can be easily removed.
c. Worn torch parts

d. Improper cutting current
e. Non-Genuuite Thermal Dynamics parts
4. Short Torch Parts Life
a. Oil or moisture in air source
When cutting a troublesome steel, it is suggested that the

torch travel speed be reduced to produce "slow speed
dross". Any required cleanup can then be done by scrapping, not grinding.
b. Exceeding system capability (material too thick)
Dross present on top of the plate (top spatter), is normally

caused by a slow torch travel speed or too high of a torch
standoff distance.
e. Improperly assembled torch
Manual 0-2811
c. Excessive pilot arc time

d. Air flow too low (incorrect pressure)
5-3
SERVICE
2. Input power not properly connected to customer's main

power panel
5.04 Troubleshooting Guide

A. General
a. Check that input power is present and unit is

properly connected (refer to Section 3.05, Input Power Connections)
Troubleshooting and repairing this unit is a process which

should be undertaken only by those familiar with high
voltage high power electronic equipment.
3. Customer's main power line fuse(s) blown

a. Check main power panel fuse(s) and replace
as required.
WARNING
4. Actual input voltage does not correspond to voltage selection inside unit
There are extremely dangerous voltage and power

levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
power electronics measurement and troubleshooting techniques.
a. Check actual line voltage vs. voltage selection

(inside of unit).
5. Unit internal fuse blown or loose
a. Fuse may blow if input voltage is higher than
voltage selection (inside unit). If blown, double
check input voltage vs. voltage selection (inside of unit) and replace fuse per Section 5.05B. If fuse blows again, components inside unit
may be faulty.
B. Basic Troubleshooting
This manual covers a basic level of troubleshooting that
requires limited dissasembly and measurements. It is
helpful for solving many of the common problems that
can arise with this system.
6. Faulty components in unit
If major complex subassemblies are faulty, the unit must

be returned to an authorized service center for repair.
a. Return unit to an authorized service center for

repair or have qualified technician repair per
Service Manual.
Follow all instructions as listed and complete each section in the order presented.
For major troubleshooting and parts replacement procedures refer to PAK Master 100XL Plus Automated
Power Supply Service Manual 0-2812.
B. AC Power indicator ON; TEMP indicator ON

1. Airflow obstructed
a. Check for obstructed air flow and correct condition.
C. How to Use This Guide

The following information is a guide to help the Customer/Operator determine the most likely causes for
various symptoms.
2. Fan blocked
This guide is set up in the following manner:
3. Unit is overheated
a. Check and correct condition
a. Allow unit to cool down for about 5 minutes.

Make sure the unit has not been operated beyond duty cycle limit.
X. Symptom (Bold Type)

Any Special Instructions (Text Type)
1. Cause (Italic Type)
4. Input line voltage is below 75% of rated level
a. Check/Remedy (Text Type)
a. Check and connect to proper input power line
Locate your symptom, check the causes (easiest listed first)

then remedies. Repair as needed being sure to verify that
unit is fully operational after any repairs.
A. AC Power

a. Return for repair or have qualified technician
repair per Service Manual.
indicator OFF
1. Switch at customer's main power panel in OFF position.

a. Close main power panel switch
SERVICE
5-4
Manual 0-2811
C. Torch will not pilot when torch is activated (hand

pendant or CNC start signal)

1. RUN/SET/LATCH switch in SET position

a. Move switch to RUN position.
G. Erratic or improper cutting output
2. Faulty torch parts
1. Poor input or output connections
a. Inspect torch parts and replace if necessary (refer to Instruction Manual supplied with torch).
a. Check all input and output connections.

2. Incorrect type and size cable on input or output
3. Gas pressure too high or too low

a. Set pressure to 70 psi (4.8 bar).
4. Torch parts missing or loose.
a. Use proper type and size cables.

H. AC Power indicator ON; Cutting output available; Fans not operating,
a. Refer to torch manual for details.
1. Fan blades blocked
a. Check and clear blades.

D. AC Power indicator ON; Fans operating; Torch
Trigger activated; No cutting output
1. Torch not properly connected to power supply

I. AC POWER indicator ON; Fans operate; No gas
flow
a. Check that torch leads are properly attached

to power supply
1. Gas not connected or pressure too low

a. Check source for at least 70 psi (4.8 bar).
2. Shield cup not properly installed on torch
2. Gas supply pressure too high
a. Check that shield cup is fully seated against

torch head (do not overtighten if screwed on)
a. Max 125 psi (8.6 bar) inlet pressure



4. Faulty torch
J. Torch cuts but not adequately

1. Drag circuit active

repair per Torch Instruction Manual.
a. Lift tip from work piece.
E. Low cutting output with no control
NOTE
1. Incorrect setting of CURRENT (A) control
At output settings higher than 35 amps, the power

supply automatically reduces output current to 35
amps if the torch tip touches the workpiece.
a. Check and adjusted to proper setting.

2. Current set too low

a. Increase current setting.

3. Torch is being moved too fast across workpiece
F. Limited output with no control
a. Reduce cutting speed (refer to Instruction

Manual supplied with torch).
1. Poor input or output connections

a. Check all input and output connections.
4. Excessive oil or moisture in torch
2. Incorrect setting of CURRENT control
a. Hold torch 1/8 inch (3 mm) from clean surface

while purging and observe oil or moisture
buildup (do not activate torch)
a. Check and adjusted to proper setting.
Manual 0-2811
5-5
SERVICE
B. Fuse Replacement
5.05 Power Supply Parts

Replacement
1. Remove the left side panel per paragraph "A"

above.
2. Locate the internal fuse above the input power
contactor on the left side of the unit.
WARNING
3. Replace the fuse. Refer to Section 6 for catalog

number.
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
4. Reinstall the left side panel per paragraph "A"

above.
A. Left Side Panel Removal

1. Remove the five screws which secure the left side
panel (viewed from front of unit) to the frame assembly.
Left Side
Panel
Internal Fuse
0.8 Amps, 600V
A-02764
A-02761
Figure 5-4 Internal Fuse Location
Screws
(5 places)
Figure 5-3 Left Side Panel Removal

NOTE
There is a ground wire connection to the Left Side
Panel on the inside of the unit. There is no need to
disconnect the ground wire.
2. Carefully pull the Left Side Panel up and away
from the unit to gain access to the inside of the
unit.
3. To reinstall the left side panel do the following:
a. Place the left side panel onto the frame and
slide the top edge under the lip on the top of
the right side panel.
b. Reinstall all the screws to secure the left side
panel.
SERVICE
5-6
Manual 0-2811
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows:
Section 6.03 Complete Power Supply Replacement
Section 6.04 Replacement Parts
Section 6.05 Options and Accessories
NOTE
Parts listed without item numbers are not shown,
but may be ordered by the catalog number shown.
B. Returns
If a product must be returned for service, contact your
distributor. Materials returned without proper authorization will not be accepted.
6.02 Ordering Information

Order replacement parts by catalog number and complete
description of the part or assembly, as listed in the parts
list for each type item. Also include the model and serial
number of the torch. Address all inquiries to your authorized distributor.
Manual 0-2811
6-1
PARTS LISTS
6.03 Complete Power Supply Replacement

Power supply includes: Work cable and ring terminal, pressure regulator/air filter, two stage air filter and operating
manual.
Description
Catalog #
PAK Master 100XL Plus Automated Power Supply Without Input Plug and Cable
3-6862
6.04 Replacement Parts

Qty
Description
Catalog #
Fuse (0.8 amp, 600V)
9-7526
1
1
1
1
1
Two Stage Air Line Filter Kit includes

Bracket, Two Stage Filter Mounting
Two Stage Air Filter Assembly
Replacement First Stage Filter
Replacement Second Stage Filter
7-7500
9-7535
9-7527
9-1021
9-1022
6.05 Options and Accessories

Qty
Description
Catalog #
Multi-Purpose Cart
7-8888
575V Transformer
9-7500
1
1
2
1
Single-Stage Filter Kit Includes Filter And Hose

Replacement Filter Body
Replacement Filter Element
Replacement Filter Hose
7-7507
9-7740
9-7741
9-7742
1
1
Computer Control Cable (CNC)

25 Foot (7.6 M)
50 Foot (15.2 M)
8-5557
8-5558
220V Single-Phase Input Power Cable
9-7512
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
Assembled Filter
Cover
Barbed
Fitting
A-02476
Optional Single-Stage Air Filter Kit
PARTS LISTS
6-2
Manual 0-2811
APPENDIX I: INPUT WIRING REQUIREMENTS
Input
Power Input
Current Input
Voltage
Freq.
1-Ph
3-Ph
1-Ph
3-Ph
(Volts)
208
230
240
380
415
460
(Hz)
50/60
50/60
50/60
50/60
50/60
50/60
(kVA)
18.9
18.9
19
21.2
21.2
21.2
(kVA)
17.3
17.3
17.5
19.1
19.4
20.4
(Amps)
91
82
79
55.9
51.2
46
(Amps)
48
43.5
42
29
27
25.6
575
Suggested Sizes (See Notes)

Fuse (Amps)
1-Ph
100
90
80
70
60
50
3-Ph
60
50
50
35
35
30
Wire (AWG)
1-Ph
2
2
2
4
6
6
3-Ph
4
6
6
8
8
8
Wire (Canada)
1-Ph
2
2
2
4
6
6
3-Ph
4
6
6
8
8
8
Requires Transformer Module
Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electrical Code
NOTES
The table above is based on the following output current & voltage: 140VDC @ 80A
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations
refer to local or national codes.
Cable conductor temperature used is 167 F (75 C).
An energy limiting fuse UL Class RK-1 (examples: BUSS LPS/LPN-RK or Gould-Shawmut AZK-A6K) should be
used to minimize damage to Plasma Cutting, Welding or power distribution equipment.
NEVER use replaceable element fuses like UL Class H, or "one-time" fuses like UL Class K5.
Flexible cable must have an outside diameter of 0.69 inches (17.5 mm) or greater.
Manual 0-2811
A-1
APPENDIX
APPENDIX II: SEQUENCE OF OPERATION

(BLOCK DIAGRAM)
LATCH
ACTION
ACTION
Close external
disconnect switch.
ON/OFF switch
to ON.
RESULT
RESULT
RESULT
RESULT
Power to system.
AC indicator blinks for 8

seconds then steady on.
Fans on.
Power circuit ready.
Gas solenoid open,

gas flows to set pressure.
GAS indicator on.
Gas flow stops.

GAS indicator off.
ACTION
ACTION
RUN/SET/LATCH switch
to SET.
RUN/SET/LATCH
switch to RUN.
ACTION
ACTION
Protect eyes and
activate torch
Torch moved away

from work (while
still activated).
RESULT
RESULT
Gas flows (2 seconds).
Main arc stops.

Pilot arc automatically
restarts.
PILOT ARC
After gas pre-flow:

DC indicator on.
Pilot relay closes.
Pilot arc established
ACTION
Torch moved within
transfer distance of workpiece.
RESULT
ACTION
Main arc transfer.

Pilot arc off.
Torch deactivated (by torch switch

release or by remote device).
RESULT
Main arc stops.
(Power supply enable signal removed.)
Gas flows (15 seconds)
NOTE - If torch is activated during
post-flow, pilot arc will immediately restart.
If torch is within transfer distance (3/8 in) of
workpiece, main arc will transfer.
After post-flow:
Gas solenoid closes, gas flow stops.
GAS indicator off.
APPENDIX
ACTION
ON/OFF switch
to OFF
RESULT
All indicators off.
Power supply fans off.
A-2
ACTION
Torch Switch
can be released.
RESULT
Transfer will continue
until torch is removed
from workpiece.
ACTION
Open external
disconnect.
RESULT
No power to system.
A-02461
Manual 0-2811
APPENDIX III: POWER SUPPLY CNC INTERFACE

DIAGRAM
NOTE
Cable connections from Cutting Machine Controller (CNC) to Plasma Power Supply.
Cutting Machine
CNC Cable
Power Supply
J22
Red
START/STOP
Black
Blue
Orange
White
Start Motion
(OK-To-Move)
Shield must be terminated
at the Cutting Machine
Manual 0-2811
Green
Shield
3
Source 15 vdc, 10ma
4
10
Not Used
11
Not Used
12
14
2A, 125 VAC

28 vdc
A-02259
A-3
APPENDIX
APPENDIX IV: DATA TAG INFORMATION
West Lebanon, NH USA 03784
Model:
S/N
Made in USA
Type of Power
Supply (Note 1)
1/3
Manufacturer's Name and/or

Logo, Location, Model and
Revision Level, Serial Number
and Production Code
Regulatory Standard Covering
This Type of Power Supply
f1
f2
Output Current Type
Duty Cycle Factor

Output Range (Amperage/
Voltage)
Plasma Cutting
Symbol
U0 =
Duty Cycle Data (Note 3)
U2
Rated NoLoad Voltage
Conventional
Load Voltage
Rated Maximum
Supply Current
Input Power
Symbol
U1
I 1max 3
1
1
1
1
I 1eff
Input Power
Specifications
(Phase, AC or DC
Hertz Rating)
Degree of Protection
Manufacturer's Electrical
Schematic File Number
and Revision Level
Rated Supply
Voltage (Note 2)
NOTES:
1. Symbol shown indicates single- or three-phase AC input,
static frequency converter-transformer-rectifier, DC output.
2. Indicates input voltages for this power supply. Most power
supplies carry a label at the input power cord showing input
voltage requirements for the power supply as built.
3. Top row: Duty cycle values.
Second row: Rated cutting current values.
Third row: Conventional load voltage values.
APPENDIX
Maximum Effective
Supply Current
A-4
Standard Symbols
AC
DC
Phase
A-03288
Manual 0-2811
This page left blank.
Manual 0-2811
A-5
APPENDIX
APPENDIX V: SYSTEM SCHEMATIC
A-02765
APPENDIX
A-6
Manual 0-2811
A-02765
Manual 0-2811
A-7
APPENDIX

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Automated Plasma

Cutting Power Supply

Manual No. 0-2811

Automated Plasma Cutting Power Supply

Notes, Cautions and Warnings ..................................................................... 1-1

Scope of Manual .......................................................................................... 2-1

Introduction .................................................................................................. 3-1

Introduction ................................................................................................. 4-1

TABLE OF CONTENTS (continued)

Introduction .................................................................................................. 5-1

Introduction ................................................................................................. 6-1

APPENDIX I: INPUT WIRING REQUIREMENTS ..................................................................... A-1

GASES AND FUMES

Throughout this manual, notes, cautions, and warnings

Use an air-supplied respirator if ventilation is not

The kinds of fumes and gases from the plasma arc

A procedure which, if not properly followed, may

Always read the Material Safety Data Sheets

For information on how to test for fumes and gases

1.02 Important Safety Precautions

Use special equipment, such as water or down draft

OPERATION AND MAINTENANCE OF

Date: November 15, 2001

This product, when used for welding or cutting,

Wear dry gloves and clothing. Insulate yourself

PLASMA ARC RAYS

Disconnect power source before performing any

Read and follow all the instructions in the Operating Manual.

Keep helmet and safety glasses in good condition.

FIRE AND EXPLOSION

Protect others in the work area from the arc rays.

Fire and explosion can be caused by hot slag, sparks, or

Use the shade of lens as suggested in the following

Less Than 300*

* These values apply where the actual arc is clearly

Provide a fire watch when working in an area where

Date: November 15, 2001

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS

Toute procdure pouvant provoquer des blessures

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,

1.05 Precautions De Securite

Coupant larc au jet de plasma produit de lnergie

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY

1.04 Note, Attention et

Lisez toujours les fiches de donnes sur la scurit

Ne touchez jamais une pice sous tension ou vive;

Utilisez un quipement spcial tel que des tables de

Nutilisez pas le chalumeau au jet de plasma dans une

Procurez une bonne aration de toutes les fumes

Le phosgne, un gaz toxique, est gnr par la fume

Ne coupez pas et ne soudez pas les conteneurs ayant

RAYONS DARC DE PLASMA

Date: November 15, 2001

ultra-violets trs forts. Ces rayons darc nuiront vos

* Ces valeurs sappliquent ou larc actuel est observ

Date: November 15, 2001

1.06 Documents De Reference

Date: November 15, 2001

1.07 Declaration of Conformity

Date: November 15, 2001

1.08 Statement of Warranty

Main Power Magnetics